Core lifter for molding apparatus

ABSTRACT

A core lifter having lifter bar with an elongate blade which carries a coupling head received in an elongate lifter bar coupling receiver formed in the base configured to permit pivotable, swiveling and/or translational misalignment or tolerance compensation during core lifter assembly, installation, and operation in a plastic formable material molding apparatus, including during mold cycling advantageously preventing core lifter binding and extending core lifter life. A preferred lifter has a lifter bar formed of a blade to which a lifter bar coupling ball is attached that is received in an elongate longitudinally extending channel having a transverse cross section complementary to the ball defining a bearing race in which the ball is received enabling slidable pivoting, swiveling and slidable movement of the ball and blade relative thereto including while the ball and blade are slidably moving along the race in a longitudinal or lengthwise direction relative to the base.

CROSS-REFERENCE

This application claims priority under 35 U.S.C. § 119(e) in U.S.Provisional Patent Application No. 62/332,594, filed May 6, 2016, theentirety of which is hereby expressly incorporated herein by reference.

FIELD

The present invention is directed to a core lifter for a moldingapparatus and more particularly to a core lifter better able to pivotand rotate about multiple axes during ejection of a molded part madewith an undercut.

BACKGROUND

In a plastic molding apparatus, a core is an additional component of amold of a plastic molding apparatus that is used to form a feature in aplastic molded part that cannot be otherwise formed by the mold or moldsof the plastic molding apparatus used to make the plastic part. Inmaking such a feature-containing plastic part, the core is disposedwithin the mold cavity to form the feature during molding of the partbut then moved out of the way when molding is completed to enable theplastic part to be removed.

When forming certain types of features, particularly undercuts, into aplastic molded part, a core lifter is used to position the core withinthe mold cavity where the core will form the desired feature, e.g.,undercut, during molding of the rest of the part. After molding of thepart is finished, the core lifter moves the core out of the way so thecore will not interfere with part removal by the lifter causing the coreto clear the feature formed by the core in the molded part. While such acore lifter can be configured so the core is a separate component thatis then mounted or otherwise attached, most core lifters are configuredwith the core formed as an integral part of the core lifter.

Core lifters are commonly used in plastic molding apparatuses thatpreferably are plastic injection molding apparatuses to help form aninternal undercut in a plastic part being molded. Core lifters do so byhelping to enable a movable core of a mold of the plastic injectionmolding apparatus used to form the internal undercut to be moved out ofthe way after the undercut-containing plastic part has been formed. Corelifters also help enable the plastic part to be ejected from the plasticinjection molding apparatus in readying the plastic injection moldingapparatus to form another substantially identical undercut-containingplastic part. Such core lifters for plastic injection moldingapparatuses are connected to the core and typically actuated by theejection system of the plastic injection molding apparatus to move thecore into position during closing of the molds of the plastic injectionmolding apparatus and to move the core out of position during ejectionof the plastic part formed with the undercut produced by the core.

In the past, custom core lifters were commonly used in plastic injectionmolding apparatuses that were made of a core blade or lifter bar seatedat a predetermined angle by mounting one end of the blade or bar at afixed angle to a coupling which slidably moved linearly along a supportmounted to ejection plates of the ejector system. In order to customdesign custom core lifters, a mold designer needed to take into accountthe amount of undercut needed, the horizontal displacement required, aswell as the distance the ejector system that the particular plasticinjection molding apparatus must travel during plastic part molding indetermining the necessary angle for the lifter. Quite often such customdesign core lifters were one time or one off designs that were not onlyexpensive to make but which could not be used in other molds, even moldsrelatively similar to the one for which they were custom designed.

U.S. Pat. No. 5,316,467 is directed to a core lifter that is intended tobe of universal construction having a core blade, e.g., lifter bar,which is pivotally mounted to a coupling fixed to a separate supportthat attaches to the ejector system. The end of the lifter bar has aheel with a pair of flat sides and a bottom with a partially sphericalconvex surface that is received in a curved dovetail of the couplingequipped with a cooperating partially spherical convex surface. Whilethe core lifter disclosed in the '466 is an improvement over a priorunsuccessful attempt at making such a universal core lifter disclosed inparent, U.S. Pat. No. 5,132,442, it still suffers from considerabledrawbacks.

While the '467 core lifter does allow an angle of the core blade orlifter bar to be varied relative to an axis transverse to the couplingdovetail that also extends transversely through the flat sides of theheel of the bar, the range of angular adjustment typically is toolimited to prevent the bar from binding and/or the core lifter fromotherwise failing during mold operation. While the '467 core lifter doespermit some angular adjustment relative to the transverse axis, ittypically offers less, if any, angular adjustment relative to an axislongitudinal to the coupling dovetail that also extends longitudinallythrough the lifter bar heel, which often is too limited to preventbinding and core lifter failure during mold operation.

Just as bad, if not worse, is the fact that the gaps between each flatside of the heel and adjacent flat dovetail sidewall can provide toomuch play thereby allowing the lifter bar to move too much in aside-to-side direction during molding, which can cause the core to beimproperly positioned in the mold during molding. This can not onlycause defective parts to be molded, but also can lead to binding andcore lifter failure if the excessive play allows the lifter bar todisplace too far to one side or the other. Frequently exacerbating theseproblems is the fact that the heel cannot move strictly in aside-to-side direction in the dovetail because the cooperating sphericalsurfaces cause the lifter bar to pivot about the longitudinal axis.Since the lifter bar heel cannot move side-to-side within the dovetailof the coupling without also pivoting, core misalignment and binding canand do occur with the '467 core lifter.

While the core lifters disclosed in U.S. Pat. No. 5,316,467 have enjoyedsubstantial commercial success, improvements nonetheless remaindesirable. For example, there are times that present day core liftersend up becoming misaligned during mold closing or during part ejection.Depending on how bad the misalignment is or becomes over time, bindingcan even occur which requires costly stoppage to fix and which can stillresult in the very mold damage they were intended to prevent.

As a result of at least these deficiencies in the '467 core lifter andother commercially available core lifters suffering from similardrawbacks, it is further believed that none of these prior art corelifters are fully articulating in any direction and therefore lack anyability to self-align. As a result of such an inability of prior artcore lifters to self-align during assembly, installation, and use duringmolding, core misalignment and mislocation, core lifter binding, andcore lifter failure occur far more commonly than believed.

SUMMARY

The present invention is directed to a core lifter for a plastic moldingapparatus that preferably is a plastic injection molding apparatushaving at least one mold in which a feature is molded into a plasticpart using such a core lifter that moves out of the way during ejectionof the molded plastic part. A core lifter of the present inventionadvantageously provides angular and tolerance compensation that not onlyprevents binding during molding but which also decreases wear duringoperation.

The core lifter includes a core blade or lifter bar and a core lifterbase. The lifter bar has a first end configured to cause a feature to beformed in material being formed by the core lifter and a second end. Forinstance, the first end can be a three dimensionally contouredfeature-molding end configured to mold plastic. The lifter bar ismovably attached to the core lifter base. For instance, the core lifterbase can contain an elongate guide shoe within which the second end ofthe lifter bar is received. The core lifter base is grounded to thematerial forming apparatus. For instance, the core lifter base can beremovably anchored to an ejector plate of the mold.

The lifter bar can pivot, swivel, and rotate about the core lifter base.For instance, the bar can pivot about a pivot axis that extendstransversely to a longitudinal centerline of the core lifter base atleast ±20 degrees about the pivot axis. Additionally, the lifter bar canswivel about a swivel axis extending downwardly through the center ofthe lifter bar. The bar can swivel at least 20 degrees about the swivelaxis, and up to 360 degrees about the swivel axis. The bar can also tiltabout a tilt axis where the tilt axis extends along a longitudinalcenterline of the core lifter base. For instance, the lifter bar cantilt at least ±10 degrees about the tilt axis.

Additionally, the core lifter can further include a guide ball that isreleasably coupled to the second end of lifter bar. The core lifter barpreferably is formed of an elongate blade that can have a removable coreattached to one end and the guide ball attached to the opposite end. Theguide ball can have a convexly rounded outer surface. The guide ball canbe a ball bearing with a recessed lifter bar end-receiving seat formedbetween a pair of spaced apart and generally parallel arms disposed onopposite sides of a portion of the lifter bar received therebetween whenmounting the ball to the lifter bar. In a preferred embodiment, the ballis a generally U-shaped ball bearing between which is disposed therecessed lifter bar end receiving seat. Where the guide ball includesthe pair of generally parallel hinge knuckle arms, the second end of thelifter bar can be received between the pair of generally parallel hingeknuckle arms. A pin can then be inserted into a bore formed in thesecond end of the bar, as well as a first bore formed in a first hingeknuckle arm and a second bore formed in a second hinge knuckle arm.

The core lifter base can have a generally U-shaped bearing race with aconcavely curved bottom and a pair of opposed concavely curved sides.Thus, the bearing race can be complementary in shape or contour withthat of the guide ball. Similarly, the guide ball can comprise agenerally spherical side outer surface and generally spherical bottom.The bearing race can also have a generally spherical bottom and a pairof opposed generally spherical sidewalls.

A lateral gap can be located between the second end of the lifter barand the guide ball. The lateral gap can allow for side-to-side movementof the second end relative to the guide ball. This side-to-side movementcan be independent of movement along the pivot axis, the tilt axis, orthe swivel axis.

The second end of the lifter bar can include a ball-and-socket couplerand the elongate guide shoe can include a ball- and socket received suchthat the bar and the core lifter base form a ball and socket connection.Once the ball and socket connection is formed, the second end of the barcan be pivotable, slidable, rotatable, and translatable about theelongate guide shoe. Similarly, the second end can be angularlyadjustable within the elongate guide shoe. Also, the second end can bepivotally adjustable within the elongate guide shoe. Additionally, thesecond end can be axially adjustable fore and aft within the elongateguide shoe. Further still, the second end can be transversely adjustablewithin the elongate guide shoe.

A coupler ball can be releasably attached to the second end of thelifter bar, such that the bar is received within the elongate guideshoe. Thus, the coupler bay can slidably ride along the elongate guideshoe. The second end of the lifter bar can have a generally I-shapedcoupling head that is received within a generally I-shaped channel thatextends generally transversely through the coupler ball. The I-shapedcoupling head can have an endwall and the I-shaped channel can have anendwall, such that the coupling head endwall is located adjacent to thechannel endwall when the coupling head is received by the channel. Thecoupling head endwall and the channel endwall can be separated by a gap,which allows relative rotational movement of the coupler ball about thecoupling head. For instance, the gap can allow relative rotationalmovement of not more than approximately 5 degrees by the coupler ballabout the coupling head. The gap can also allow relative rotationalmovement of not more than approximately 2.5 degrees by the coupler ballabout the coupling head. The gap can only allow relative movement of notmore than approximately 1 degree by the coupler ball about the couplinghead. Additionally, a gap can separate a sidewall of the generallyI-shaped coupling head from a sidewall of the generally I-shapedchannel, which would allow for relative side-to-side movement betweenthe coupler ball and the coupling head.

The coupler ball can slide over the coupling head, and a retainer canextend through a plurality of bores formed in the coupler ball and abore formed in the second end of the lifter bar. The retainer canfunction as a pivot such that the coupler ball is rotatable relative tothe coupling head. The coupler ball can also be movable about three axesrelative to the core lifter base.

The elongate guide shoe can additionally have a pair of oppositelyinwardly extending core lifter bar inwardly extending lifter bar guidearms forms a guide slot about the elongate recessed channel. The couplerball is slidable along the elongate recessed channel, and the pair ofoppositely inwardly extending lifter bar guide arms prevents the couplerball from being pulled out of the guide slot. Additionally, the pair ofoppositely inwardly extending lifter bar guide arms limit angularrotation of the coupler ball about a generally transversally axis thatextends through a centerline of the coupler ball. More specifically, thepair of oppositely inwardly extending lifter bar guide arms can limitangular rotation of the coupler ball to no more than approximately 15degrees. Alternatively, the pair of oppositely inwardly extending lifterbar guide arms can limit angular rotation of the coupler ball to no morethan approximately 10 degrees. Additionally, the pair of oppositelyinwardly extending lifter bar guide arms can limit angular rotation ofthe coupler ball to no more than approximately 5 degrees.

These and other objects, features and advantages of this invention willbecome apparent from the following detailed description of the inventionand accompanying drawings.

DRAWINGS

Preferred exemplary embodiments of the invention are illustrated in theaccompanying drawings in which like reference numerals represent likeparts throughout and in which:

FIG. 1 is a perspective view of a core lifter assembly of the presentinvention;

FIG. 2 is a perspective exploded view of a core blade or lifter barcoupler of the lifter and receiver of a core lifter base that isanchored to part of the mold;

FIG. 3 is a perspective exploded view of the core blade or lifter barcoupler assembly;

FIG. 4 is an enlarged fragmentary perspective view of the couplerassembly;

FIG. 5 is an enlarged perspective view of a coupler ball of the couplerassembly;

FIG. 6 is a fragmentary front elevation of the coupler ball adjustablymounted to a coupling head at a free end of the core blade or lifter barforming a coupler assembly where play between the coupler ball andcoupling head facilitates alignment and dynamic adjustment during corelifter assembly, core lifter installation, core lifter use, and moldoperation;

FIG. 7 is a perspective view of the core lifter base illustrating anelongate longitudinally extending bearing raceway in which the couplerball of the coupler assembly is slidably, pivotably and rotativelyreceived when assembly of the core lifter is completed;

FIG. 8 is a fragmentary front elevation of the coupler ball adjustablymounted to a coupling head to form the core blade or lifter bar couplerassembly that is slidably, pivotable and rotatively received in thebearing raceway of the receiver of the core lifter base.

FIG. 9 is a front elevation view of a core lifter assembly of thepresent invention depicting side-to-side angular adjustment orself-alignment of an angular range of up to ±10 degrees about a firstaxis extending along a longitudinal centerline of the bearing racewaythat also extends through a center of the ball of the coupler assembly;

FIG. 10 is a top plan view of the core lifter assembly of FIG. 9depicting side-to-side angular adjustment or self-alignment of angularrange of up to ±10 degrees about the first axis extending along alongitudinal centerline of the bearing raceway that also extends througha center of the ball of the coupler assembly;

FIG. 11 is a front elevation view of the core lifter assembly of FIG. 9depicting fore-aft angular adjustment or self-alignment of an angularrange of up to ±20 degrees about a second axis extending transversely tothe longitudinal centerline of the bearing raceway that also extendsthrough a center of the ball of the coupler assembly where the secondaxis is translatable along the bearing raceway;

FIG. 12 illustrates use and operation of a plurality of core lifterassemblies of the present invention installed in a molding apparatuswith the mold closed forming a plastic part where a molding end of eachcore lifter apparatus forms an internal undercut in the plastic partbeing molded; and

FIG. 13 illustrates use and operation of the plurality of core lifterassemblies during ejection of the formed plastic part where the coreblade or lifter bar of each core lifter assembly is able to adjust oralign by being able to translate in a side-to-side direction, in afore-aft direction longitudinally along the raceway, in a side-to-sidedirection generally transversely relative to the raceway, rotatively ina fore-aft direction, and/or rotatively in a side-to-side directionduring mold closing and mold opening.

Before explaining one or more embodiments of the invention in detail, itis to be understood that the invention is not limited in its applicationto the details of construction and the arrangement of the components setforth in the following description and illustrated in the drawings. Theinvention is capable of other embodiments or being practiced or carriedout in various ways. Also, it is to be understood that the phraseologyand terminology employed herein is for the purpose of description andshould not be regarded as limiting.

DETAILED DESCRIPTION

FIGS. 1-13 illustrate a preferred embodiment of a core lifter 40 of thepresent invention for use in a molding apparatus 42, which preferably isa formable material molding apparatus 44, and which more preferably aplastic molding apparatus 45, such as the plastic injection moldingapparatus 45 depicted in FIGS. 12 and 13, which advantageously isconfigured to angularly adjust, including to provide angular alignmentcompensation, during molding apparatus operation that preferably also isa core lifter 40 of self-aligning construction in that the core lifter40 also is pivotable along a plurality of axes while also being able toprovide side-to-side tolerance compensation during molding apparatusoperation. Such a core lifter 40 constructed in accordance with thepresent invention is able to more smoothly operate in a wider range ofmolding apparatuses and under a greater range of operating conditionswhile lasting longer thereby advantageously facilitating smoothermolding apparatus operation leading to increased molding apparatusuptime.

With reference to FIGS. 1-11, the core lifter 40 has a core blade orlifter bar 46 with an elongate substantially straight lifter bar blade31 equipped with a actuator end 55 at one end that is or includes athree dimensionally contoured feature-molding core 48 carried by theblade 31. The lifter bar 46 has a pivotable, slidable, rotatable, andtranslatable coupling arrangement 50 disposed at an opposite end of theblade 31 that is a coupling end 52 of the bar 46 or blade 31 preferablyconfigured to provide at least a plurality of, preferably at least aplurality of pairs of, i.e., at least three, (a) angular adjustment, (b)pivotable adjustment, (c) fore-and-aft axial translatable adjustment,and/or (d) transverse side-to-side adjustment producing a core lifter 40in accordance with the present that is at least partially self-aligningand/or tolerance compensating, and which preferably is substantiallycompletely self-aligning and/or tolerance compensating. As is discussedin more detail below, the coupling arrangement 50 preferably includes acore lifter bar coupling head 57 carried by the blade 31 at or adjacentthe coupling end 52 with the core lifter bar coupling head 57 having ashape or contour complementary to a core lifter bar coupling receiver 56of a core lifter base 58 in which the coupling head 57 is movably,preferably slidably, received.

The lifter bar coupling receiver 56 preferably is elongate recessed intothe base 58 with the receiver 56 extending longitudinally or in alengthwise direction relative to the base 58. The base 48 preferably isformed of an elongate body 61 that is generally rectangular both in alengthwise direction and transverse direction of the base 48. The lifterbar coupling receiver 56 can and preferably does extend longitudinallysubstantially the length of the body 61 of the base 58.

In a preferred embodiment, the lifter bar coupling receiver 56 has across-section or cross-sectional contour or shape that is substantiallycomplementary to a shape or contour, preferably a peripheral shape orperipheral contour, of the coupling head 57 enabling the head 57 to bemovably received in the receiver 56 thereby movably coupling the lifterbar 46 and core 48 to the base 58. With the base 58 preferably fixed topart of the molding apparatus 42, preferably an ejector plate or ejectorplate assembly of the apparatus 42, receipt of the head 57 in thereceiver 56 movably couples the lifter bar 46 and core 48 to the base 58in a manner permitting the head 57 to translate along the receiver 56enabling the bar 46 to substantially simultaneously move in a generallylinear direction relative to the base 58 during mold cycling duringmolding apparatus operation.

While the three-dimensionally contoured molding end 55 of the lifter bar46 preferably is integrally shaped or formed to provide a core 48 with acore molding face 51, which can be and preferably is athree-dimensionally contoured molding face 51, which forms or molds acorrespondingly three-dimensionally shaped feature in the part beingmolded (not shown), it is contemplated that a core lifter 40′ of thepresent invention can further be configured to have a replaceablethree-dimensionally contoured molding end 55′ with a removable orreplaceable core 48′, such as depicted in FIG. 3, which is a componentseparate from the blade 31′ of the lifter bar 46′ that is attached ormounted to a core-mounting end 53 of such a removable core carryinglifter bar blade 31′ during assembly of a lifter bar 46′ in making ofsuch a removable core carrying core lifter 40′. FIG. 3 shows a dashed orphantom line 33 delineating where the separate core 48′ engages with thecore-mounting end 53 of the blade 31′ of the core lifter bar 46′ of sucha core lifter 40′ of the present invention that is constructed andarranged and/or configured to removably accept one of at least aplurality of different cores 48′ having a plurality of differentthree-dimensionally contoured molding faces 51′, lengths, widths,depths, sizes or shapes.

With continued reference to FIG. 3, separate core 48′ is of removableconstruction, which can be and preferably is of replaceableconstruction, and which can be and preferably is three-dimensionallycontoured to removably or releasably engage with a core-mounting end 53of the blade 31′ of the lifter bar 46′ to removably attach the core 48′to the blade 31′ of the bar 46′ with the core-mounting end 53 preferablybeing complementarily three-dimensionally contoured such that areleasable core attachment joint 59 is formed at dashed or phantom line33 in FIG. 3 between the core 48′ and the end of the blade 31′ of thelifter bar 46′ when the core 48′ is attached thereto. In a preferredembodiment, the core 48′ and core-mounting end 53 of the blade 31′ arecomplementarily three-dimensionally contoured to produce a coreattachment joint 59 of snap-fit construction that enables the core 48′to be snapped onto the core-mounting end 53 of the lifter bar blade 31′during assembly of lifter bar 46′ and to be snapped off from thecore-mounting end 53 of the blade 31′ during removal of the core 48′from blade 31′ of the bar 36′ of the core lifter 40′.

A core 48′ and core lifter 40′ with a lifter bar 46′ having a lifter barblade 31′ with a core-mounting end 53 configured to enable attachmentand detachment of core 48′ thereby advantageously enables a plurality ofdifferent cores 48′ having a molding face 51 with plurality of differentthree-dimensional shapes, three-dimensional contours, and/or sizes to beinterchangeably used with the same or single core lifter 40′ of theinvention. In a preferred embodiment, such a core 48′ and core lifter40′ of the present invention with a lifter bar 46′ having a blade 31′with such a core-mounting end 53 configured to form, provide or producea core-attachment joint 59 that enables removable or releasable mountingof the core 48′ to the core-mounting end 53 of the blade 31′ of thelifter bar 46′ advantageously enables cores 48′ having a plurality ofdifferently shaped or three-dimensionally contoured molding faces 48′ tobe interchangeably mounted, e.g., attached to and detached from thecore-mounting end 53 of the blade 31′ of the lifter bar 46′, to the samesingle core lifter 40′.

With continued reference to FIG. 3, separate core 48′ is of removableconstruction, which can be and preferably is of replaceableconstruction, and which can be and preferably is of toollesslyattachable and/or of toollessly removable construction, with a preferredembodiment of such a core 48′ of the invention being a componentseparate from lifter bar blade 31′ and lifter bar 46′ of core lifter 40′with the lifter bar blade 31′ of the lifter bar 46′ having acore-mounting end 53 configured to form a core attachment joint 59 thatenables the core 48′ to be toollessly attached to the core-mounting end53 of the blade 31′ of bar 46′ and/or toollessly detached from themounting end of the blade 31′ of bar 46′. In one such preferredembodiment, in accordance with that discussed above, the core 48′ andcore-mounting end 53 of the blade 31′ of the lifter bar 46′ of corelifter 40′ is configured to form a core attachment joint 59 of snap-fitconstruction that is constructed and arranged or otherwise configured toenable the core 48′ to be toollessly snapped onto the core-mounting end53 of the blade 31′ of the lifter bar 46′ and toollessly snapped off orfrom the core-mounting end 53 of the blade 31′ of bar 46′. Although notshown in FIG. 3, where the core-attachment joint 59 is of snap-fitconstruction, the core-mounting end 53 of the blade 31′ of lifter bar46′ of core lifter 40′ has a three-dimensionally contoured portion thatsnap-fittingly engages with a substantially complementarythree-dimensionally contoured portion of the core 48′ forming a snap-fitattachment joint 59 therebetween thereby enabling the core 48′ to besnapped onto and/or snapped off of the core-mounting end 53 of the blade31′ of bar 46′ of core lifter 40′ preferably without the use of anytools (e.g., “tool-less” joint 59) or fasteners (“fastener-less” joint59).

Such a removable core-carrying core lifter 40′ configured for attachmentof a core 48′ during core lifter assembly advantageously produces a corelifter 40′ of universal construction further in accordance with thepresent invention that is adaptable and even customizable byadvantageously enabling removable and/or replaceable attachment of cores48′ having different shapes, sizes, and other three-dimensional moldingface contours and configurations tailor made for the particular moldingapplication, part or component being molded, and/or molding apparatus inwhich the custom-tailored or custom-shaped core 48′ and removablecore-carrying core lifter 40′ are installed. In other words, a corelifter 40′ constructed in accordance with the present invention likethat depicted in FIG. 3 with a lifter bar 46′ having a lifter bar blade31′ with a core-mounting end 53 configured to receive a removable orreplaceable core 48′, preferably via snap-fit attachment, enables cores48′ with a molding face 51′ having at least a plurality of differentshapes, three-dimensional contours, lengths, widths, depths,thicknesses, and/or sizes to be removably attached thereto in producinga highly customizable or configurable core lifter 40′ of the inventionwith a core 48′ customized for the particular molding application, partbeing molded, and/or molding apparatus. Such a core lifter 40′configured to removably receive such a separate core 48′ advantageouslynot only enables the core 48′ to be replaced due to wear and/or tearwithout having to replace the rest of the core lifter 40′, but whichalso enables such a core lifter 40′ of the present invention to be usedin the same molding apparatus with a plurality of differently shaped,contoured, or sized cores 48′ used with either the same mold ordifferent molds depending on the application and/or part being molded.

With reference once again to FIGS. 1 and 2, the coupling arrangement 50is formed of (a) a pivotable, translatable and transversely adjustableball-and-socket coupler 54 disposed at the coupling end 52 of the lifterbar 46 with the coupler 54 preferably formed of or otherwise includingthe coupling head 57, and (b) an axially translatable ball-and-socketcoupler receiver 56 of an elongate core lifter base 58 that operablycouples with the coupler 54, preferably coupling with the head 57,thereby coupling the lifter bar 46 to the base 58 in a manner thatenables at least one of, and preferably at least a plurality oftranslation, pivoting and/or tolerance-compensating adjustment of thecoupler 54, preferably also the coupling head 57 and at least part ofthe lifter bar 46, relative to the coupler receiver 56 and base 58during mold cycling during molding apparatus operation. In a preferredembodiment of the coupling arrangement 50, the coupler 54, preferablywith or including the coupling head 57, releasably couples with the base58 by being received by the coupler receiver 56 thereby operativelycoupling the coupler 54, preferably with or including the coupling head57, and the lifter bar 46 to the base 58 in a manner that enablestranslation, pivoting and tolerance-compensating adjustment of thecoupler 54, preferably also the coupling head 57, and at least part ofthe lifter bar 46, relative to the coupler receiver 56 and base 58during mold cycling during molding apparatus operation.

In the preferred embodiment depicted in FIGS. 1 and 2, the coupling head57 of the lifter bar 46 is slidably and rotatively received in thecoupler receiver 56 of a core lifter base 58 fixed to an ejector plateor ejector plate assembly of the molding apparatus 42 enabling thelifter bar 46, including its actuator end 55 and/or core 48 carriedthereby, to pivot, rotate, and translate relative to or about the base58 during installation, use and operation of the core lifter 40 duringmolding apparatus operation. With continued reference to FIGS. 1 and 2,the coupling head 57 is or includes a ball-and-socket type coupler 54 ofthe lifter bar 46, which preferably is carried or otherwise attached tothe lifter bar blade 31, which is slidably, pivotably and/or rotativelyreceived in the coupling receiver 56 formed in the base 58 enabling thelifter bar 46, including core 48, to translate, pivot and/or rotaterelative to the base 58 thereby advantageously helping to keep the corelifter 40 from binding during mold cycling during operation of moldingapparatus 42. As discussed in more detail below, tolerance compensationcan be provided between the coupling head 57 of the lifter bar 46 andlifter bar coupling head receiver 56 of the base 58 in a manner thatprovides some play therebetween, which can and preferably advantageouslydoes help prevent the core lifter 40 from binding during mold cyclingduring molding apparatus operation.

With additional reference to FIGS. 12 and 13, one or more such corelifters 40 constructed in accordance with the present invention areassembled and installed in a molding apparatus 42 that preferably is aformable-material molding apparatus 44 and which more preferably aplastics injection molding apparatus 45, with the core lifter base 58 ofeach core lifter 40 attached, such as by one or more fasteners, to partof the molding apparatus 42 for movement of the base 58 substantially inunison therewith during molding apparatus operation in producing one ormore molded parts. In the preferred embodiment shown in FIGS. 12 and 13,the base 58 of each core lifter 40 is removably attached by one or morefasteners, e.g., screws or bolts, to an ejector plate assembly 60 orejector plate 61 of the molding apparatus 42 substantially immovablyfixing or grounding the core lifter base 58 thereto. When the base 58 ofeach core lifter 40 is fixed or grounded to an ejector plate assembly 60or ejector plate 61 of the molding apparatus 42, the base 58 of the corelifter 40 moves substantially in unison with the ejector plate 61 of theejector plate assembly 60 during each molding cycle of molding apparatusoperation.

As is also depicted in FIGS. 12 and 12, the elongate lifter bar 46 ofeach core lifter 40 used in the molding apparatus 42 extends through acorresponding angled lifter guide slot 160 also referred to as a primaryrelease direction slot, into a mold cavity 162 formed in a mold 164 thatcan (a) have a bottom mold or bottom mold half 166, (b) have a top moldor top mold half 168, or (c) be formed by mating top and bottom halves166 and 168 of the mold 164 when cycled closed by the molding apparatus42 during molding apparatus operation. As previously indicated, the base58 of each core lifter 40 is fixed with fasteners 170 to a respectiveejector plate 61 of an ejector plate assembly 60 of the moldingapparatus 42 with the elongate bar 46 of each core lifter 40 extendingupwardly through its respective guide slot 160 into cavity 162 of mold164 in which the core 48 disposed at the free end of the lifter bar 46of corresponding core lifter 40 is used to mold a complementarily shapedfeature into the part 65 being molded in the cavity 162 during eachmolding cycle of opening and closing of the mold 164 during operation ofthe molding apparatus 42.

During opening and closing of the mold halves, the bar 46 of each corelifter 40 can and preferably does slidably ride and be guided in and bythe lifter guide slot to guide movement of the core 48 in the moldcavity. In FIGS. 12 and 13, the bar 46 of each core lifter 40 of themolding apparatus 42 is slidably guided in a corresponding guide slotthat extends into the mold cavity and is generally in line with thethree-dimensional feature or undercut formed by the core 48 in themolded part. The portion of the lifter bar 46 that carries or isintegrally formed with the core 48 extends into the mold cavity when themold halves are closed to cause the core 48 to mold a feature of a shapecomplementary to the core 48 in the part being molded and which helpsclear the molded part during ejection. An example of the construction ofsuch a molding apparatus 42 that is a plastic injection moldingapparatus 45 for which use of one or more core lifters 42 of the presentinvention is particularly well suited is shown and described in U.S.Pat. No. 5,316,466, the entirety of which is expressly incorporatedherein by reference.

With reference once again to FIGS. 2-5, the core lifter bar coupler 54has its coupling head 57 disposed at a coupling end 52 of the corelifter bar blade 31 of the core lifter bar 46. FIG. 6 depicts apreferred coupling head 57 of the coupler 54 that is a generally round,preferably substantially spherical, core lifter bar coupling ball 64which is shown in FIG. 6 detached from the blade 31 of the lifter bar 46thereby illustrating in FIG. 6 the coupling ball 64 in more detail byshowing the ball 64 all by itself. FIG. 7 shows in more detail thecoupler receiver 56 of the core lifter base 58 that receives the corelifter bar coupling ball 64 when the core lifter bar 46 is assembled,preferably coupled, to the base 58 in a manner that permits slidabletranslation of the lifter bar 46 along the base 58 during moldingapparatus operation. The base 58 of such a core lifter 40 of the presentinvention is shown all by itself in FIG. 7 with the core lifter bar 46detached or disengaged to show the base 58, including its couplerreceiver 56, in more detail.

With additional reference to FIG. 8, the coupler receiver 56 preferablyis, includes, is configured with, or is configured as an elongategenerally straight core lifter bar guide shoe 66 integrally formed inthe base 58 extending longitudinally along the base 58 that movablyreceives the core lifter bar coupling ball 64 thereby movably couplingthe bar 46 and any core 48 carried by the bar 46 to the base 58 in amanner that slidably guides movement of the ball 64 and blade 31 of thebar 46 along the shoe 66 in a lengthwise direction relative to the base58. In a preferred embodiment, the guide shoe 66 preferably is orincludes an elongate longitudinally extending channel 124 formed in thebase 58 that extends in a lengthwise direction of the base 58 along thebase 58 and which has a cross-sectional-contour generally complementaryto that of the coupling head 57 of the lifter bar 46. Where the couplinghead 57 is or includes coupling ball 64, the guide shoe 66, includingsuch an elongate longitudinally extending channel 124 of the shoe 66formed in the base 58, preferably has a cross-sectional contourtransverse to the direction of coupling ball translation relative to thebase 58 that is substantially complementary to that of the coupling ball64.

When the lifter bar coupling ball 64 is received in the core lifter barguide shoe 66 in the manner depicted in FIGS. 1 and 8, the lifter bar 46becomes movably coupled to the lifter base 58 enabling the ball 64 andblade 31 of the lifter bar 46 to translate preferably by slidinggenerally in a straight-line direction along the shoe 66 substantiallyalong the length of the channel 124 of the shoe 66 while being slidablyguided by the shoe 66 in a lengthwise direction relative to the base 58in either direction along the shoe 66 during molding apparatusoperation. As the coupled ball 64 translates generally in a straightline longitudinal or lengthwise direction relative to the base 58 duringmolding apparatus operation, so generally does the rest of the lifterbar 46, including the lifter bar blade 31 and core 48, because the bar46 is operatively connected to the ball 64, such as in the mannerdepicted in FIG. 2, thereby enabling such movement, preferably viatranslation, of the bar 46 relative to the base 58, as well as relativeto parts of the molding apparatus 42 to or in which the base 58 isfixed, during mold cycling during molding apparatus operation. Tofacilitate smooth and long lasting operation, the lifter bar couplingball 64 preferably is made of a durable material that can be andpreferably which also is reduced friction construction, such as acoupling ball 64 made of or from a round metal or metallic ball, e.g., around or spherical steel ball bearing, of hardened construction. In apreferred embodiment, the lifter bar coupling ball 64 is made of or froma carbide ball with one such preferred coupling ball 64 being made of orfrom a round or spherical carbide ball bearing.

With specific reference to FIGS. 2-5, the lifter bar coupling ball 64 isdisposed at an end of the blade 31 of the lifter bar 46 opposite thecore 48 with the ball 64 slidably coupling with an elongate guide shoe66 of the coupler receiver 56 formed in the base 58 enabling the ball 64to at least translate or move in the guide shoe 66 relative to the base58 in either direction along the base 58 along substantially the lengthof the guide shoe 66, including while being able to pivot, swivel,and/or rotate about at least one axis and preferably at least aplurality of axes relative to the base 58 (a) during self-adjustment,self-alignment, tolerance compensation, misalignment compensation,and/or misalignment adjustment of the core lifter 40 during assembly ofthe core lifter 40 and/or installation of the core lifter 40 in themolding apparatus 42, and (b) during cycling of the mold(s) of themolding apparatus 42 in which the core lifter 40 is installed duringoperation of the molding apparatus 42. As a result of the elongatesubstantially straight channel 124 of the guide shoe 66 having agenerally transverse cross-section that is substantially complementaryto or with a generally spherical shape of at least the portion of thecoupling ball 64 that comes in contact with the channel 124, thecoupling ball 64 and channel 124 of the shoe 66 forms a lifter bar guidearrangement along which the lifter bar 46 translates relative to thebase 58 in a substantially straight line along the channel 124 and guideshoe 66 during core lifter self-adjustment, self-alignment, tolerancecompensation, misalignment compensation, and/or misalignment adjustmentin or along a fore-aft direction of the core lifter 40 in thelongitudinal or lengthwise direction relative to the base 58.

The slidable movement of the guide ball 64 in the guide shoe 66 of acore lifter 40 of the present invention facilitates movement thatpreferably is self-aligning movement or self-adjusting movement of thelifter bar 46 relative to the guide shoe 66, relative to base 58, andrelative to one or more parts of the molding apparatus 42 in a mannerthat advantageously prevents binding of the bar 46 or core 48 of thecore lifter 40 with any part of the mold apparatus 42 during operationof the mold apparatus 42. Where the molding apparatus 42 is a plasticinjection molding apparatus 45, slidable movement of the ball 64 in thechannel 124 of the guide shoe 66 also facilitates movement of the blade31 of the lifter bar 46 relative thereto, relative to base 58, andrelative to one or more parts of the plastic injection molding apparatus45 during mold closing, during injection molding of a plastic part 65(FIGS. 12 and 13), and during mold opening, including during plasticpart ejection during mold opening.

In the preferred core lifter embodiment shown in the drawing figures,the core lifter bar coupling ball 64 can be and preferably is attachedto the coupling end 52 of the blade 31 of the lifter bar 46 by a ballcoupling joint 47 formed between a three-dimensionally contouredcoupling end 52 of the blade 31 and a three-dimensionally contouredlifter bar coupling end receiving socket 49 formed in the ball 64 thatis configured to receive the three-dimensionally contoured coupling end52. As discussed below in more detail, the coupling end 52 of the blade31 of the lifter bar 46 and the coupling socket 49 formed in the ball 64can form a ball coupling joint 47 where there is some play or tolerancecompensation between the ball 64 and lifter bar coupling end 52 of thecore lifter bar blade 31. In another preferred embodiment, the ball 64is substantially immovably fixed to the end 52 of the blade 31 of thelifter bar 46 with the coupling joint 47 preferably configured in amanner that facilitates substantially immovable fixing of the ball 64 tothe end 52 of the blade 31 of the bar 46.

With continued reference to FIGS. 2-5, a retainer 62 can be used to helpattach the coupling ball 64 to the end 52 of the blade 31 of the lifterbar 46, including when the ball 64 and lifter bar blade end 52 areconfigured to form a coupling joint 47 when engaged with one another inthe manner depicted in FIG. 5. Where configured to help facilitatelifter bar and/or core alignment, adjustment or tolerance compensation,such a retainer 62 can be employed to help attach the ball 64 to the end52 of the blade 31 of the bar 46 to form a tolerance-compensatingcoupling joint 47 but which preferably also is configured to enable orotherwise facilitate self-alignment, self-adjustment, tolerancecompensation, misalignment compensation, and/or misalignment adjustmentof the ball 64 relative to the coupling end 52 of the blade 31 therebyadvantageously helping to facilitate self-alignment, self-adjustment,tolerance compensation, misalignment compensation, and/or misalignmentadjustment of the lifter bar 46 and/or core 48 relative to the base 58and/or some part of the molding apparatus 42 in which the core lifter 40has been installed.

Such a coupling joint 47 formed between the ball 64 and coupling end 52of the lifter bar blade 31 preferably is of releasable or detachableconstruction enabling detachment or disassembly of the ball 64 from theend 52 of the blade 31 enabling a worn ball 64 to be replaced with a newone, if desired. In the preferred embodiment depicted in FIGS. 2-5, acoupling joint 47 of releasable or detachable construction is formedwith or using such a retainer 62 that is inserted into engagement withthe ball 64 and coupling end 52 of the blade 31 to positively andsecurely attach the ball 64 to the blade 31 and which is a retainer 62that is disengaged or otherwise removed from the ball 64 and couplingend 52 of the blade 31 to enable detachment of the ball 64. Whendetached, the ball 64 can be replaced with another ball 64, such as anew ball 64, one of a plurality of different types of balls having aplurality of different hardness's, outer surface contours, shapes, sizesand/or the like that is releasably and positively secured to thecoupling end 52 of the blade 31 using the retainer 62.

Where the coupling joint 47 is a tolerance compensating joint formedbetween the ball 64 and coupling end 52 of the lifter bar blade 31, theball 64 preferably is releasably or detachably mounted to the couplingend 52 of the blade 31 of the lifter bar 46 in a manner that alsoprovides some play therebetween that allows or facilitatesself-alignment, self-adjustment, tolerance compensation, misalignmentcompensation, and/or misalignment adjustment of the lifter bar 46 and/orcore 48 relative to the base 58 and/or some part of the moldingapparatus 42 in which the core lifter 40 has been installed, includingduring molding apparatus alignment. While it is contemplated that such atolerance compensating joint 47 can be formed without the use of anyretainer 62, the preferred embodiment of the joint 47 shown in FIGS. 2-5employs a retainer 62 that preferably is of removable or detachableconstruction thereby also enabling removal and replacement of ball 64,if needed.

When the ball 64 is attached, coupled or otherwise mounted to the lifterbar blade 31 in forming such a tolerance compensating and releasablecoupling joint 47, such as in the manner depicted in FIGS. 2-5, limitedrelative movement therebetween advantageously enables at least one ofand preferably at least a plurality of angular adjustment andtranslation by permitting limited rotational and/or pivotable movementand/or limited translational movement between the ball 64 and lifter barblade 31′. Such a tolerance compensating releasable coupling joint 47that employs retainer 62 preferably is a tolerance compensatingreleasable coupling joint 47 that is configured to enable or otherwisefacilitate alignment adjustment of the core 48 and bar 46 relative tothe ball 64 and/or base 58 when the ball 64 is received in the guideshoe 66 of the base 58. In one such preferred embodiment, the joint 47is configured to provide tolerance compensation by being configured toprovide a very slight amount of play between the three-dimensionallycontoured coupling end 52 of the lifter bar 46 and the socket 49 formedin the ball 64 because doing so advantageously facilitatesself-alignment, self-adjustment, tolerance compensation, misalignmentcompensation, and/or misalignment adjustment of the lifter bar 46 and/orcore 48 relative to the base 58 and/or some part of the moldingapparatus 42 in which the core lifter 40 has been installed, includingduring molding apparatus operation.

Where a retainer 62 is employed, a preferred retainer 62 is an elongategenerally cylindrical retainer pin 108 like that shown in FIG. 4 thatextends through a pair of spaced apart arms 74, 76 of coupling socket 49and through part of the lifter bar 46 at or adjacent the coupling end 52of the bar 46 in the manner depicted in FIGS. 2 and 3. As shown in FIGS.2-6 and 8, a preferred core lifter embodiment has the coupling ball 64attached to the coupling end 52 of the blade 31 of the lifter bar 46with such an elongate generally cylindrical retainer pin 108 in a mannerthat permits or allows some slight relative movement or play between theball 64 and blade 31 of the bar 46, particularly at or adjacent thecoupling end 52 of the blade 31 where the ball 64 is attached thereto.Where the ball 64 is attached at or to the coupling end 52 of the blade31 of the bar 46 in a manner that permits some misalignment adjusting ortolerance compensating play, the ball 64 is attached, such as viaretainer 62, preferably via retain pin 108, in a manner that can andpreferably does permit some slight relative movement or play between theball 64 and the blade 31 of the bar 46, particularly at or adjacent theend 52 of the blade 31 of the bar 46.

In another preferred embodiment, the coupling ball 64 is attached to thecoupling end 52 of the blade 31 of the lifter bar 46 using a joint 47 ofsimilar or substantially identical construction employing a method andarrangement of attachment that substantially immovably fixes the corelifter bar coupling ball 64 to the core lifter bar blade 31 in a mannerthat prevents relative movement between the ball 64 and blade 31 of thebar 46 during use and operation of such a core lifter 40, includingduring molding apparatus operation. In one such preferred embodiment,the coupling ball 64 is attached to the coupling end 52 of blade 31 witha retainer 62, such as a retainer pin 108, in a manner thatsubstantially immovably fixes the ball 64 to the coupling end 52 of theblade 31 producing a lifter bar 46 having an immovably fixed lifter barcoupling ball 64 at the end of the bar 46 that movably couples with thebase 58. In another such preferred embodiment, the ball 64 is affixed tothe end 52 of the bar 46 in a manner that substantially immovably fixesthe ball 64 to the bar 46. In another preferred embodiment, the couplingball 64 and coupling end 52 of the lifter bar blade 31 are threedimensionally configured substantially as shown in FIGS. 2-6 and 8-9 butwhich lack or do not require any retainer 62 to produce such a joint 47that substantially immovably mounts the ball 64 to the blade 31 of thelifter bar 46.

Even when the ball 64 substantially immovably mounted to the blade 31,such a joint of substantially immovable or fixed construction can be ofa releasable or detachable configuration that enables the ball 64 to bedetached or disengaged from the end 52 of the blade 31 of the lifter bar46. In the preferred embodiment shown in the drawings where the joint 47includes retainer 62, preferably retainer pin 108, removal of theretainer 62 preferably by removing the pin 108 from being engaged withthe ball 64 and coupling end 52 of the core lifter bar blade 31 enablesdetachment or disengagement of the ball 64 from the blade 31.

Where the coupling ball 64 is attached at or to the end 52 of the lifterbar 46 in a manner that allows some relative movement therebetween, suchas by being configured with some play therebetween, the ball 64 can beand preferably is attached by a retainer 62 to a lifter bar bladecoupling head 68 formed at or in a free end, preferably the coupling end52, of the blade 31 of the lifter bar 46 forming an alignment adjustingmotion-limited lifter bearing knuckle joint 70 that can be andpreferably is configured, e.g., dimensioned, so there is a limitedamount of side-to-side play, preferably a predetermined amount ofside-to-side play, movement off centerline (FIG. 6), GAP 1 or GAP 2(FIG. 8) of at least 0.005 inches therebetween that facilitatesalignment adjustment, e.g., automatic adjustment and/or self-alignmentof the ball 64 relative to the lifter bar 46. The ball 64 and head 68preferably are dimensioned to provide a predetermined amount ofside-to-side play, movement off centerline, or GAP 1 of at least about0.005 inches that enables side-to-side play or side-to-side alignmentadjustment of ball 64 relative to head 68 (or vice versa). Depending onthe size of the scalable core lifter 40, the ball 64 and head 68 oflifter bar blade 31 can be dimensioned and toleranced to produce aside-to-side play, movement off centerline, GAP 1 or GAP 2 of as much as0.030 inches per side or a total of side-to-side play of 0.060 inches.In a preferred embodiment, such a core lifter 40 of the presentinvention is dimensioned and toleranced to have a side-to-side play,movement off centerline, GAP 1 of between 0.005 inch and 0.1 inch andpreferably between about 0.005 inch and 0.060 inches.

By the ball 64 being mounted to the lifter bar blade coupling head 68 ofthe blade 31 of the lifter bar 46 in the manner depicted in FIG. 6, itallows the ball 64 to move side-to-side relative to the bar 46independently of pivoting, rotation or swiveling as side-to-sideadjustment permitted by such play occurs without changing the angle ofpivot, swivel or rotation of the bar 46. Such side-to-side relativemovement between the ball 64 and head 68 advantageously permitsside-to-side adjustment of the bar 46 independent of swiveling,pivoting, or rotation of the bar 46 facilitating self-alignment andself-adjustment of the core lifter 40 during core lifter assembly,during core lifter installation into a molding apparatus 42, during corelifter use, and during molding apparatus operation.

With reference to FIGS. 4-6, the ball 64 is generally round andpreferably substantially spherical with the coupling socket 49 formed ofa lifter bar end receiving seat 80 recessed in the ball 64 that receivesa free end of the lifter bar 46 that preferably is the coupling end 52of the bar 46 during assembly of the bar 46 to the ball 64. As is bestshown in FIG. 6, the lifter bar end receiving seat 80 preferably isformed of a channel 94 formed in the ball 64 between which is disposed apair of spaced apart and generally parallel arms 74, 76 that bracketopposite sides of the portion of the coupling end 52 of the lifter bar46 that is received in the channel 94 during assembly of the bar 46 tothe ball 64.

Extending outwardly of the seat 80 and channel 94 and extendingoutwardly of or from the arms 74, 76 of the ball 64 is a rounded outerbearing cap 75 having a convexly rounded outer surface 100 thatpreferably is a generally round bearing surface 102 of the ball 64. Whenthe ball 64 is received in the elongate longitudinally extending channel124 of the core lifter bar guide shoe 66 of the receiver 56 when thelifter bar 46 is movably attached to the base 58, the rounded bearingsurface 102 of the ball 64 movably, preferably slidably, bears againstor contacts an internal bearing surface 125 that extends along theinterior of the channel 124 of the shoe 66 of the receiver 56 formed inthe base 58 substantially along the length of the channel 124 or shoe66. In a preferred embodiment, the ball 64 preferably is a bearing, morepreferably a substantially spherical ball bearing, which preferably is ahardened bearing, which more preferably is a carbide ball bearing,having a coupling socket 49 formed therein that is formed of a lifterbar end receiving seat 80 that is formed of a channel 94 defined betweenarms 74, 76.

Where the ball 64 is attached to the coupling end 52 of the lifter bar46 in a manner that permits some relative movement therebetween, such aswhen the ball 64 and coupling end 52 are configured to have some playtherebetween, the ball 64 can be and preferably is formed of asubstantially round or substantially spherical ball bearing 72 with thecoupling socket 49 formed of a recessed lifter bar end or lifter barcoupling head receiving seat 80 formed by a channel 94 formed throughthe bearing 72 or ball 64. As shown in FIG. 6, channel 94 issubstantially straight and extends from and through one side of thebearing 72 or ball 64 to and through an opposite side of the bearing 72or ball 64.

Where the ball 64 is attached to the coupling end 52 of the lifter bar46 in a manner that permits some relative movement therebetween, apreferred ball 64 is formed of or from a generally U-shaped ball bearing72 having an outer bearing cap 75 from which a pair of spaced apart andgenerally parallel hinge knuckle arms 74, 76 outwardly, preferablyupwardly, extend defining a hinge knuckle yoke 78 with a recessed corelifter bar coupling head receiving seat 80 disposed between the knucklearms 74, 76. Outer bearing cap 75 preferably is defined by a convexlyrounded outer surface 100 that preferably is a rounded outer bearingsurface 102 that preferably is substantially smooth, preferably at leastpartially spherical, and which can be substantially spherical. As bestshown in FIG. 5, this includes corresponding convexly rounded outersides or side surfaces 77, 79 of knuckle arms 74, 76 of the ball 64which are each at least partially spherical, preferably is substantiallyspherical, and preferably also substantially smooth. This also includesa convexly rounded bottom or bottom outer surface 103 of the ball 64which also is at least partially spherical, preferably is substantiallyspherical, and preferably also substantially smooth.

When the ball-and-socket coupler 54 is received in the coupler receiver56 of the core lifter base 58, the outer bearing surface 102 of thegenerally hemispherical outer bearing cap 75 of the U-shaped ballbearing 72 of the bar-coupling guide ball 64 of the lifter bearingknuckle joint 70 slidably rides along the receiver 56 in a manner thatpermits rotation, twisting, swiveling, and/or angular changes about atleast a plurality of axes, preferably at least a plurality of pairs,i.e., at least three, of axes, and producing a core lifter 40constructed in accordance with the present invention possessing at leasta plurality of degrees of freedom, and preferably possessing at least aplurality of pairs, i.e., at least three, degrees of freedom that issubstantially self-aligning.

When the ball 64 is received in the socket provided by receiver 56, thecore lifter 40 can swivel 150, such as depicted in FIG. 8, about aswivel axis 152 of the core lifter bar 46 that extends longitudinally orlengthwise through the lifter bar 46 and a center 154, e.g., centerpoint, of the ball 64 and which preferably also is substantiallycoincident with the longitudinal lifter bar axis 122. As is shown inFIG. 8, lifter bar blade swivel axis 152 extends longitudinally orlengthwise through the center or through a centerline of the blade 31 ofthe lifter bar 46 and through a point of the ball 64 that defines or isdisposed at the center of the ball 64. In the preferred embodiment shownin FIG. 8, the center 154, e.g., center point, of the ball 64 is locatedin the channel 94 of the lifter bar receiving seat 80 of the lifter barcoupling socket 49 with the center 154 of the ball 64 being disposed ina portion of the lifter bar blade coupling end 52 or lifter bar bladecoupling head 68 of the blade 31 of the lifter bar 46.

In a preferred embodiment, the center 154 of the ball 64 is the same asor substantially coincident with the geometric center or geometriccenter point, e.g., three-dimensional geometrical or three-dimensionalcenter point, of the ball 64 if the ball 64 were a solid spherical ball,e.g., solid round ball or solid sphere. Such a center point or center154 of the ball 64 is the location of the x, y, z point in or of thecenter of the ball 64 if the ball 64 was an uninterrupted round ball oruninterrupted sphere.

With continued reference to FIG. 8, the blade 31 and lifter bar 46 areoriented generally uprightly with the blade 31 of the bar 46 extendingupwardly from the base 58 in a direction generally parallel to avertical axis 135 of the base 58 that vertically bisects the base 58 andextends through the center 154 of the ball 64 generally perpendicular toa horizontal axis 137 of the base 58 that preferably bisects the channel124 or bearing race 126 and extends through the center 154 of the ball64 movably and rotatively captured in the channel 124 and bearing race126. With the lifter bar 46, blade 31 and ball 64 oriented as shown inFIG. 9, the vertical axis 135 of the base 58 is substantially coincidentwith the longitudinal core lifter bar blade center axis 122 that alsoextends through the center 154 of ball 64.

The lifter bar blade coupling head 57 is disposed at or adjacent thecoupling end 52 of the elongate and straight blade 31 of the lifter bar46 that carries the ball 64 with the ball 57 preferably being coupled tothe coupling head 57 at or adjacent the coupling end 52 of the bar 46,such as in the manner shown in FIGS. 2-6 and 8-9 and described in moredetail elsewhere herein. As depicted in FIGS. 2-5 and 8-9 and discussedin more detail elsewhere herein, the coupling head 57 is athree-dimensionally contoured head disposed at or adjacent the couplingend 57 of the blade 31 of the lifter bar 46 that is configured forcoupling with the ball 64 in a manner that securely and positivelyretains or mounts the ball 64 thereto.

Such a core lifter 40 constructed in accordance with the presentinvention can swivel 150 such that the blade 31 of the lifter bar 46rotates about the swivel axis 152 extending through the bar 46 at least10 degrees, preferably at least 20 degrees, and preferably between 20degrees and 360 degrees. Because the ball 64 is round or spherical, theball 64 preferably rotates substantially in unison with the blade 31 ofthe bar 46 about the swivel axis 152 when the bar 46 is swivelingrelative to or about the longitudinal central base axis 135 and/or thelongitudinal central lifter bar blade axis 122. In a preferredembodiment, core 48 and lifter bar 46 can swivel about the swivel axis152 more than 360 degrees, e.g., can continuously swivel about theswivel axis 152. In a preferred embodiment for each of the above swivelangular extents, the blade 31 of the lifter bar 46 preferably rotates orspins about its central longitudinal axis 122 when swiveling about theswivel axis 152, such as when swiveling to self-align, automaticallyadjust, tolerance compensate, compensate for misalignment, and/ormisalignment adjust during assembly of core lifter 40, duringinstallation of core lifter 40 into molding apparatus 42, and/or duringuse and operation of the core lifter 40, including during mold cycling,part or component ejection, and/or the like during operation of moldingapparatus 42. Where the blade 31 of the lifter bar 46 extends generallyperpendicularly upwardly from the base 58 straight up from the base 58in the manner depicted in FIG. 8, the swivel axis 152 preferably issubstantially coincident with both the vertical central longitudinalbase axis 135 and the central longitudinal lifter bar axis 122, such asis shown in FIG. 8.

With reference to FIGS. 5 and 8, the core lifter bar coupling head 68 isformed in the coupling end 52 of the lifter bar 46 that preferably is agenerally I-shaped coupling head 68 with a pair of spaced aparttransversely extending knuckle arm guide channels 82, 84 formed inopposite sides 86, 88 of the lifter bar 46 at or adjacent the couplingend 52 from which a respective coupling head guide rib 90, 92 extendsoutwardly at or adjacent the free end of the bar 46. With reference toFIGS. 4-8, the lifter bar blade coupling head receiving seat 80 formedin the ball 64 preferably is a generally transversely extending channel94 of generally I-shaped cross-section having a pair of spaced apart,opposed and generally parallel guide slots 96, 98, each of whichslidably receive and guide a corresponding rib 90, 92 of the lifter barblade coupling head 68 during assembly of the lifter bearing knucklejoint 70. The seat 80 includes guide slots 96, 98, formed a distancebelow or radially inwardly of the outer surface 100 of the ball 64 whichthereby also define a pair of opposed generally inturned coupler ballguide ribs 104, 106 slidably received in and guided by a correspondingone of the knuckle arm guide channels 82, 84 of the lifter bar bladecoupling head 68 when coupling head ribs 90, 92 of the coupling head 68are received in guide slots 96, 98 during assembly of the core lifterbearing knuckle joint 70.

With reference to FIGS. 1-6, the ball 64 engages and preferably coversthe coupling head 68 of the lifter bar 46 and preferably fits like a capover the coupling head 68 of the when the ball 64 is slid over the head68 during assembly of the ball 64 to the coupling head 68 of the lifterbar 46 forming the core lifter bearing knuckle joint 70 with the outerbearing surface 102 of the portion of the ball 64 that defines thebearing cap 75 functioning as a bearing when the ball 64 is slidablydisposed in the receiver 56 of the core lifter base 58. The couplinghead 68 can and preferably does have an endwall 85 at its free end thatoverlies an endwall 95 of channel 94 formed in ball 64 and which canabut or stop against endwall 95 to limit relative motion between theball 64 and head 68 when assembled together to form core lifter bearingknuckle joint 70. As depicted in FIGS. 3-6, lifter bar blade couplinghead endwall 85 can be and preferably is generally flat or substantiallyplanar and coupler ball channel endwall 95 can be and preferably also isgenerally flat or substantially planar.

If desired, the coupler ball 64 can be attached to the coupling head 68of the blade 31 of the lifter bar 46 by a retainer 62 that can be andwhich preferably is a pin 108 that can be and which preferably is ofelongate and generally cylindrical construction. In the preferredembodiment of a core lifter 40 of the present invention shown in thedrawing figures, assembly of the core lifter bearing knuckle joint 70preferably is completed by inserting the retainer 62, preferably pin108, through a ball coupling retainer receiving bore 110 in one of theknuckle arms 74, through a ball coupling retainer receiving bore 112 inthe coupling head 68, and through a ball coupling retainer receivingbore 114 in the other one of the knuckle arms 76 in the manner depictedin FIGS. 2-5 and 8-9 thereby forming knuckle joint 70 and coupling theball 64 to the bar 46. Where the ball 64 is coupled by a retainer 64,such as retainer pin 108, to the coupling head 68 of the lifter bar 46at the coupling end 57 of the bar 46, the ball coupling retainerreceiving bores 110 and 114 of the ball 64 are through bores that aresubstantially coaxial with one another with one of the bores 110extending completely through one arm 74 of the ball 64 and the other oneof the bores 114 extending completely through the other arm 76 of theball 64 as shown in FIG. 6. Where the ball 64 is coupled by a retainer64, such as retainer pin 108, to the coupling head 68 of the lifter bar46 at the coupling end 57 of the bar 46, the coaxial bores 110 and 114can and preferably do extend through the ball 64 at or adjacent acenterline 155 of the ball 64 as depicted in FIG. 8 in a directiontransverse or generally perpendicular to the longitudinal or lengthwiseextent of the lifter bar 46 coupled thereto by retainer 64, e.g., byretainer pin 108. As disclosed in more detail elsewhere herein anddepicted in FIGS. 8 and 9, except for the recessed seat 80, e.g.,channel 94, of the coupling socket 49 formed in the ball 64, the ball 64is round and preferably is substantially spherical.

Where the ball 64 is coupled by a retainer 64, such as retainer pin 108,to the coupling head 68 of the blade 31 of the lifter bar 46 at thecoupling end 57 of the blade 31 of the bar 46, the ball couplingretainer receiving bore 112 of the lifter bar 46 can and preferably doesextend through both guide ribs 90 and 92 of the coupling head 68 of theblade 31 of the lifter bar 46 at or adjacent the coupling end 57 of theblade 31 of the bar 46 in a direction generally transverse to thelongitudinal or lengthwise direction of the bar 46, such as is shown inFIGS. 2-4, with the bore 112 preferably being generally centrallylocated in the middle of each rib 90, 92 of the bar 46. When the ball 64is coupled to the head 68 of the blade 31 of the lifter bar 46 at thecoupling end 57 thereof with the oppositely outwardly extending ribs 90and 92 received in a corresponding one of the oppositely outwardlyextending rib-receiving slots 96 and 98 formed in opposite sides of thechannel 94 of the lifter bar blade coupling head receiving seat 80formed in the ball 64 that defines the lifter bar coupling socket 49 ofthe ball 64, the ball 64 preferably is securely and positively coupledor attached to the lifter bar 46.

Where the ball 64 and bar 46 are coupled to one another, such as by orusing a retainer 64, e.g., retainer pin 108, in a manner that permitssome relative movement therebetween, such as by being configured withsome play therebetween, the ball 64 is coupled with or attached to thecoupling head 68 of the lifter bar 46 in a manner that permits somerelative pivoting motion between the ball 64 and coupling head 68 of thebar 46 about a transverse pivot axis 156 generally transverselyextending through the ball 64 in a direction that is (a) transverse orgenerally perpendicular to the bar 46 and the channel 124 or bearingrace 126 of the guide shoe 66 of the receiver 56 in the base 58, (b)transverse or generally perpendicular to the longitudinal or lengthwiseextent of the channel 124, bearing race 126, and base 58, and/or (c)transverse or generally perpendicular to the longitudinal or lengthwiseextent of the lifter bar 46. Where the ball 64 is coupled to the lifterbar 46 by a retainer 64 that preferably is a retainer pin 108 in amanner that permits some relative movement therebetween, the pin 108 notonly extends through at least part the ball 64 and the coupling head 68of the blade 31 of the lifter bar 46 in a direction transverse orgenerally perpendicular to the longitudinal or lengthwise extent of thebar 46 in coupling the ball 64 to the bar 46, but the pin 108 (alongwith the coaxially aligned bores 110, 112 and 114 that receive the pin108) can and preferably does define or function as the transverse pivotaxis 156, such as depicted in FIGS. 8 and 9, about which the ball 46 canpivot at least slightly, preferably at least 1°, relative to the bar 46,its coupling end 57, and its coupling head 68, while the ball 64 iscoupled to the bar 46, including during core lifter assembly, corelifter installation into a molding apparatus 42, during core lifter use,and during molding apparatus operation.

Where the ball 64 is coupled to the lifter bar 46 by a retainer 64 thatpreferably is a retainer pin 108 in a manner that permits some relativemovement therebetween, the pin 108 extends through coaxial bores 110 and114 in ball 64 and bore 112 in lifter bar 46 disposed between andcoaxial with bores 110 and 114 in ball 64 while the outwardly extendingribs 90 and 92 of the coupling head 68 are respectively received in therib-receiving slots 96 and 98 formed in the sides of the channel 94 ofthe coupling socket 49 in the ball 64 forming the hinge knuckle joint 70between the ball 64 and head 68 of the blade 31 of the bar 46. The pin108 (and coaxial bores 110, 112 and 114 that receive the pin 108) canand preferably does function as a pivot, i.e., the pin 108 is or definesthe pivot, about which the ball 64 can pivot a limited amount relativeto the head 68 of the bar 46 at or adjacent the coupling end 57 of thebar 46 in facilitating core lifter assembly, core lifter installation,core lifter use, core lifter operation and/or molding apparatusoperation. In such a preferred embodiment, the pin 108 (and coaxialbores 110, 112 and/or 114 that receive the pin 108) can and preferablydoes define or extend along a transverse pivot axis 156 about which theball 64 pivots or rotates relative to the head 68 of the bar 46 at oradjacent the coupling end 57 of the bar 46 in helping to providetolerance compensation and/or alignment or misalignment adjustmentduring core lifter assembly, installation of core lifter 40 into amolding apparatus 42, and/or use of the core lifter 42 including duringmold cycling during plastics injection molding operation of the moldingapparatus 42. In at least one such embodiment, such as depicted in FIGS.8 and 9, the pin 108 (and coaxial bores 110, 112 and/or 114 that receivethe pin 108) can and preferably does define or extend along a transversepivot axis 156 that also extends through the center 154 and/ortransverse centerline 155 of the ball 64 in a direction transverse tothe longitudinal or lengthwise direction of the bar 46 and which also isgenerally transverse to the channel 124 and bearing race 126 duringnormal use and operation of the core lifter 40 during normal use andoperation of the molding apparatus 42. Where the pin 108 of such a corelifter embodiment defines the generally horizontally extending pivotaxis 156 extending through the center 154 and/or along the transversecenterline 155 of the ball 64 transverse to the lifter bar 46 and base58, the pin 108 defines the pivot about which the ball 64 can andpreferably is able to pivot at least a limited amount relative to thehead 68 of the blade 31 of the bar 46 during core lifter installation,core lifter use, and/or molding apparatus operation.

In one such preferred core lifter embodiment, the ball 64 is coupled tothe lifter bar 46 by a retainer 64 that preferably is a retainer pin 108in a manner that permits some relative movement therebetween, the ball64 and coupling head 68 of the blade 31 of the bar 46 are configured topermit at least 1° of relative pivoting or relative pivotable movementbetween the ball 64 and head 68 of blade 31 of bar 46, e.g., permit theball 64 to pivot or rotate 1° or ±0.5° about the head 68 of the lifterbar blade 31, but no more than 5°. In another such preferred embodiment,the ball 64 is coupled to the lifter bar 46 by a retainer 64 thatpreferably is a retainer pin 108 in a manner that permits some relativemovement therebetween, the ball 64 and coupling head 68 of the blade 31are configured to permit at least 0.5° of relative pivoting or relativepivotable movement between the ball 64 and head 68 of blade 31, e.g.,permit the ball 64 to pivot or rotate at least 0.5° or at least ±0.25°about the transverse pivot axis 156 relative to the head 68 of the blade31, but allows no more than 1°, e.g., no more than ±0.5°, relativepivoting or relative pivotable movement therebetween. In still anothersuch preferred embodiment, the ball 64 is coupled to the lifter bar 46by a retainer 64 that preferably is a retainer pin 108 in a manner thatpermits some relative movement therebetween, the ball 64 and couplinghead 68 of the blade 31 are configured to permit at least 1° of relativepivoting or relative pivotable movement between the ball 64 and head 68of blade 31, e.g., permit the ball 64 to pivot or rotate at least 1° orat least ±0.5° about the transverse pivot axis 156 relative to the head68 of the blade 31, but allows no more than 2°, e.g., no more than ±1°,relative pivoting or relative pivotable movement therebetween. In yetanother such preferred embodiment, the ball 64 is coupled to the lifterbar 46 by a retainer 64 that preferably is a retainer pin 108 in amanner that permits some relative movement therebetween, the ball 64 andcoupling head 68 of the blade 31 are configured to permit at least 1° ofrelative pivoting or relative pivotable movement between the ball 64 andhead 68 of lifter bar blade 31, e.g., permit the ball 64 to pivot orrotate at least 1° or at least ±0.5° about the transverse pivot axis 156relative to the head 68 of the blade 31 of the bar 46, but allows nomore than 3°, e.g., no more than ±1.5°, relative pivoting or relativepivotable movement therebetween. In a further such preferred embodiment,the ball 64 is coupled to the blade 31 of the lifter bar 46 by aretainer 64 that preferably is a retainer pin 108 in a manner thatpermits some relative movement therebetween, the ball 64 and couplinghead 68 of the blade 31 of the bar 46 are configured to permit at least1° of relative pivoting or relative pivotable movement between the ball64 and head 68 of the blade 31 of the bar 46, e.g., permit the ball 64to pivot or rotate at least 1° or at least ±0.5° about the transversepivot axis 156 relative to the head 68 of the blade 31 of the bar 46,but allows no more than 5°, e.g., no more than ±2.5°, relative pivotingor relative pivotable movement therebetween.

To facilitate enabling at least some relative pivoting or rotationbetween the ball 64 and lifter bar blade coupling head 68, the head 68and the ball 64 preferably are configured so that there is a space orgap between the lifter bar blade coupling head endwall 85 and couplerball receiver channel endwall 95 as best depicted in FIG. 11. Where itis desired to increase the angular range that the ball 64 can rotaterelative to the head 68 about axis 156, the spacing or distance betweenthe lifter bar coupling head endwall 85 and lift bar blade coupling headreceiving channel endwall 95 can be increased, or the head endwall 85and channel endwall 95 can be substantially complementarily curved, e.g.have an arcuate-shape, relative to one another, if desired. In at leastone preferred embodiment, the endwall 85 of the coupling head 68 formedat or adjacent the coupling end 57 of the blade 31 of the lifter bar 46is curved and the endwall 95 of the channel 94 of the lifter bar bladehead coupling socket 49 formed in the ball 64 also is curved, with thecurved lifter bar coupling head endwall 85 and curved lift bar couplinghead receiving channel endwall 95 being complementarily curved tofacilitate relative rotation or pivoting between the lifter bar bladecoupling head 68 and ball 64 pivotably coupled to the head 68.

Where configured to permit limited relative rotation therebetween, sucha core lifter coupling ball 64 and lifter bar blade coupling head 68 areconfigured so their respective endwalls 85, 95 permit no greater than a5 degree relative angular rotation therebetween, e.g., a 5 degreeangular rotation range, about axis 156, preferably no greater than 2.5degrees relative angular rotation therebetween, e.g., a 2.5 degreeangular rotation range, about axis 156, and more preferably no greaterthan about a 1 degree relative angular rotation therebetween, e.g., a 1degree angular rotation range, about axis 156. Where configured topermit such limited angular rotation between the ball 64 and lifter barblade coupling head 68 about axis 156, such a core lifter bearingknuckle joint 70 configured to permit such relative angular or pivotingadjustment of the ball 64 and lifter bar blade coupling head 68 of sucha core lifter 40 of the present invention advantageously helpsfacilitate self-alignment of the core lifter 40 during assembly of theball 64 to the coupling head 68, installation of the core lifter 40 tothe molding apparatus 62, as well as during core lifter use and moldingapparatus operation.

Where it is desired to limit the amount of rotational play between theball 64 and lifter bar blade coupling head 68, e.g. limit or preventrelative rotation therebetween, the ball 64 and head 68 can beconfigured so that the head endwall 85 and channel endwall 95 abut orstop against one another when the pin 108 is inserted attaching the ball64 to the head 68. Where there is very little rotational play or evensubstantially no play, with the exception of side-to-side playtherebetween discussed elsewhere herein, the lifter bar 46 and ball 68preferably rotate, swivel, and move substantially in unison therewithduring installation into molding apparatus 62, and/or during moldingapparatus operation.

With reference to FIGS. 4-8, lifter bar blade coupling head 68 and corelifter ball 64 can be and preferably are configured with side-to-sidespacing or a gap therebetween when coupled together that permitsside-to-side relative movement therebetween when coupled together bypermitting the ball 64 to move relative to head 68 a limited amount in adirection transverse to the longitudinal or lengthwise direction of theblade 31 of the lifter bar 46 advantageously helping facilitateautomatic core lifter adjustment and/or core self-alignment, includingduring assembly, installation, and/or molding apparatus operation. Sucha core lifter 40 constructed with a lifter bar coupling head 68 and ball64 that couple together with a knuckle joint 70 configured to permitside-to-side relative movement between the ball 64 and head 68,preferably is constructed or configured with or to provide (a) aside-to-side spacing or gap 118 between the ribs 90, 92 of the lifterbar blade coupling head 68 and walls 97, 99 (FIG. 6) of the respectiverib-receiving slots 96, 98 of the lifter bar blade couplinghead-receiving channel 94 of the lifter bar blade coupling head socket49 formed in the ball 64 and/or (b) a side-to-side spacing or gap 120between the ribs 104, 106 that extend outwardly from the channel 94formed in the ball 64 and the walls 87, 89 of respective rib-seatingchannels 82, 84 of head 68 as best depicted in FIG. 8 in order to enablethe ball 64 to transversely float on the coupling head 68 of the lifterbar blade 31 when the ball 64 is coupled thereto by enablingside-to-side relative movement between the ball 64 and head 68 in adirection transverse to the longitudinal or lengthwise direction of theblade 31 or bar 46. When the ball 64 is received in the channel 124 andbearing race 126 formed in the base 58 thereby substantiallyconstraining or preventing sideways, side-to-side or transverse movementof the ball 64 within the channel 124 and race 126 relative to the base58, the construction of such a tolerance or misalignment compensatingcoupling joint 70 advantageously permits at least the head 68 of thelifter bar 46 and preferably also at least part of the elongate blade 31of the bar 46 that extends outwardly from the head 68, to move relativeto the ball 64 at least slightly in a side-to-side or sideways indirection that is generally transverse to the longitudinal core lifterbar blade centerline or core lifter bar central longitudinal axis 122.When the core lifter bar coupling and guide ball 64 is received in theguide shoe 66 of the coupler receiver 56 of the core lifter base 58, theplay or tolerance(s) between the ball 46 and head 68 of the blade 31from such a coupling joint 70 of tolerance and/or misalignmentcompensating construction produces such gaps 118 and/or 120 extending ina transverse direction between the ball 64 and lifter bar blade couplinghead 68, such as depicted in FIG. 8, thereby advantageously providing alimited amount of side-to-side, sideways or transverse core lifterself-alignment, tolerance compensation, and misalignment adjustment byenabling the lifter bar blade 31 to transversely move relative to theball 64 a limited amount relative to the central longitudinal lifter barblade axis 122. During such transverse self-aligning, tolerancecompensating and/or misalignment adjustment, the head 68 of the lifterbar blade 31 slidably rides along pin 108, which serves as a transverseself-aligning, tolerance compensating and/or misalignment adjustmentguide that guides or constrains side-to-side or sideways movement of thehead 68 relative to the ball 68 and core lifter base 58 in a directiongenerally transverse to the longitudinally extending lifter bar bladecenter axis 122.

FIGS. 2, 7 and 8 illustrate the core lifter base 58 and the guide shoe66 of the lifter bar coupler receiver 56 of the base 58 in more detailthat receives the bar-coupling and guide ball 64 of the ball-and-socketcoupler 54 at the end of the blade 31 of the lifter bar 46 in anelongate recessed channel 124 of the guide shoe 66 of the receiver 56formed in the body 61 of the base 58 that defines a generally U-shapedbearing race 126. With continued reference to FIGS. 2 and 7, the channel124 or bearing race 126 has a rounded, preferably generally circularinternal cross-section taken transverse to the longitudinal direction ofthe base 58 with the channel 124 or bearing race 126 having (a) an openmouth 128 at one end 67 of the base 58 through which the ball 64 isslidably inserted during assembly of the ball 64 and lifter bar 46 tothe base 58, and (b) an elongate lifter bar guide slot 130 extendinglongitudinally along a top surface 63 of the body 61 of the base 58 thatcommunicates with the channel 124 or bearing race 126 through which thelifter bar 46 extends and along which the blade 31 or bar 46 can beslidably guided when the ball 54 is received in the channel 124 orbearing race 126. As best shown in FIG. 7, bearing race 126 has (a) aconcavely curved bottom or bottom surface that is at least partiallyspherical and preferably substantially spherical in contour, and a pairof opposed concavely curved sides or sidewalls that are each at leastpartially spherical and preferably substantially spherical in contourforming bearing race 126 complementary in shape or contour with that ofthe ball 64. If desired, the channel 124 or bearing race 126 can have anopen mouth 128, 132 at both or opposite ends 67, 69 of the base 58providing a ball-insertion entryway at either end of the channel 124 orbearing race 126 as depicted in FIG. 7.

As best shown in FIG. 7, the bearing race 126 and/or channel 124preferably extends longitudinally or in a lengthwise direction relativeto the base 58 substantially the length of the base 58 and the lifterbar or blade guide slot 130 preferably also extends longitudinally or ina lengthwise direction relative to the base 58 substantially the lengthof the base 58. In the preferred core lifter embodiment shown in thedrawings, the channel 124 and/or bearing race 126 extends the entirelength of the body 61 of the base 58, the lifter bar or blade guide slot130 also extends the full length of the body 61 of the base 58, and thechannel 124 and/or bearing race 126 has a lift bar coupling ballreceiving mouth 128 and 132 at each end of the body 61 of the base 58.Such a channel 124, bearing race 126 and guide slot 130 constructionadvantageously enables the ball 64 and blade 31 of lifter bar 46 totranslate in a longitudinal or lengthwise direction, e.g., fore-aftdirection, along the base 58 during insertion of the ball 64 into thechannel 124 or bearing race 126 during assembly of the lifter bar 46 tothe base 58, during installation of an assembled core lifter 40 to themolding apparatus 42, as well as during use and operation of theassembled core lifter 40 during operation of the molding apparatus 42.

With continued reference to FIGS. 2, 7, and 8, the guide slot 130 iselongate, substantially straight, and extends between a pair ofoppositely inwardly extending lifter bar guide arms 134, 136 each ofwhich extend inwardly from a respective one of the sides 71, 73 of thebase 58. As best shown in FIGS. 7-9, each one of the lifter bar bladeguide arms 134, 136 has a respective elongate, generally straight, andsubstantially flat lifter bar blade guide bearing flat 138, 140 alongwhich a respective side 87, 89 of a corresponding guide channel 82, 84of the blade 31 of the lifter bar 46 can slidably ride during assembly,installation, self-alignment, core lifter use, and molding apparatusoperation.

The core lifter bar blade guide arms 134, 136 extend toward one anotherbut preferably are spaced apart from one another defining a lifter barblade guide slot 130 therebetween that extends along respective upperportions of a lifter bar coupling ball receiving and guiding bearingrace 126 having a generally circular transverse cross-section extendinggreater than 180 degrees, preferably greater than 285 degrees, and morepreferably greater than about 300 degrees around the core lifter barcoupling ball 64 received therein, permitting the lifter bar couplingball 64 to rotate in the bearing race 126 relative to the base 58 aswell as translate or move along the bearing race 126 and the base 58with the opposed lifter bar blade guide arms 134, 136 interfering withremoval of the ball 64 outwardly through the guide slot 130 therebypreventing disengagement of the lifter bar 46 from the base 58. In thepreferred core lifter embodiment shown in the drawings, the core lifterbar blade guide arms 134, 136 are spaced apart by the guide slot 130 andextend along respective upper portions of such a bearing race 126 thathas a generally transverse circular cross-section that extends at least235 degrees, at least 285 degrees, and at least 300 degrees around theball 64 received in the bearing race 126 while permitting the ball 64 torotate within the bearing race 126 while enabling the ball 64 the movealong the bearing race 126. Preferably, the core lifter bar guide arms134, 136 are spaced apart by the guide slot 130 extend alongside such abearing race 126 having a generally transverse circular cross-sectionthat extends at least 235 degrees, at least 285 degrees, and at least300 degrees around the ball 64 received in the bearing race 126 andabout a longitudinal centerline 158 of the race 126 that extends throughthe center point 154 of the ball 64 while permitting the ball 64 torotate within the bearing race 126 while also substantiallysimultaneously enabling the ball 64 the move along the bearing race 126with the arms 134, 136 interfering with the ball 64 being pulled out theguide slot 130.

As discussed in more detail below, longitudinal centerline 158 extendsthrough the center point 154 of the core lifter bar coupling ball 64also defining a longitudinal axis 158 of rotation of the ball 64 aboutthe center point 154 and rotational axis 158 in a side-to-side directiontransverse or generally perpendicular to the longitudinal or lengthwisedirection of the base 58. As such, it should be readily apparent fromFIGS. 1, 2, and 7-11, since the blade 31 is coupled to the ball 64received in the bearing race 126 thereby coupling the lifter bar 46 tothe base 58, the blade 31 and bar 46 pivots or otherwise movesside-to-side relative to the base 58 substantially in unison withside-to-side pivoting of the ball 64 about axis 156 within the bearingrace 126 and translates in a fore-aft direction relative to the base 58substantially in unison with fore-aft translation of the ball 64 alongthe bearing race 126. In addition, the ball 64 can pivot about axis 156and translate substantially simultaneously within the bearing race 126in a fore-aft longitudinal or lengthwise direction relative to the base58 with the blade 31 and bar 46 also substantially simultaneouslypivoting or moving side-to-side relative to the base 58 whilesubstantially simultaneously translating in the fore-aft directionrelative to the base 58 substantially simultaneous with the side-to-sidepivoting and fore-aft movement of the ball 64 within or along thebearing race 126.

With reference to FIGS. 8-10, if desired, the space between the opposedlifter bar blade guide bearing flats 138 and 140 can be greater than thewidth of the blade 31 of the lifter bar 46 and/or wider than the spacebetween opposed lifter bar blade sidewalls 86 and 88, but is no greaterthan three times lifter bar blade width, and preferably is no greaterthan two times lifter bar blade width, enabling the ball 64 to pivot ina side-to-side, sideways or transverse direction relative to the base 58about the elongate longitudinally extending center axis 158 of thebearing race 126 an angular extent, α, of no greater than ±15° in eitherdirection relative to the axis 158 before one of the lifter bar bladeguide channel walls 87 and/or 89 and/or shoulders 81 and/or 83 abuts orstops against a respective adjacent one of the lifter bar blade guidebearing flats 138 and 140, such as in the manner depicted in FIG. 9. Thespace between the guide bearing flats 138 and 140 of the preferred corelifter embodiment shown in FIGS. 9 and 10 is greater than the width ofthe core blade or lifter bar 46 between the walls 87, 89 of therespective knuckle arm guide channels 82 and 84 and which can be andpreferably is less than the width between the sidewalls 86 and 88 of thecore blade or lifter bar 46 with one of the guide channel walls 87, 89abutting or stopping against part of a respective adjacent one of thebearing flats 138 and/or 140 allowing an angular extent, α, ofside-to-side, sideway or transverse pivoting or rotation of the blade 31and ball 64 of the lifter bar 46 about longitudinal ball and bearingrace center axis 158 of at least ±5° relative to the vertical centrallongitudinal base axis 135 and preferably no greater than about ±10°relative to the vertical central longitudinal base axis 135 as shown inFIG. 9. This arrangement permits side-to-side, sideways or transversepivoting of the blade 31 of the lifter bar 46 about the longitudinalball and bearing race center axis 158 forming an acute angular extent,α, between the vertical central longitudinal base axis 135 and thecentral longitudinal lifter bar blade axis 122 that can range between 0°and ±25° but which preferably can range or extend from axis 135 at least±5° and preferably at least about ±10°, e.g., ±10°±2.5°.

In the preferred core lifter embodiment shown in FIGS. 9 and 10, thebase 58, core lifter bar blade 31 and core lifter bar coupling ball 64are configured to produce a core lifter 40 where the blade 31 pivots orrotates about side-to-side lifter bar pivot axis 158 an angular extent,α, of ±10° or a total angular extent of 20°. The lifter bar 46 is shownin FIG. 10 with the lifter bar 46 a located in a first maximum outermostangular position when the blade 31 a of the bar 46 a is pivoted orrotated about axis 158 in one sideways or transverse direction and withthe lifter bar 46 b located in a second maximum outermost angularposition when the blade 31 b of the bar 46 b is pivoted or rotated aboutaxis 158 in an opposite sideways or transverse direction depicting amaximum angular extent, α, of about 20° about which the blade 31 of thebar 46 can pivot or rotate about axis 158. As previously discussed,side-to-side pivoting or rotation of the ball 64, blade 31 and bar 46about axis 158 is limited by the lifter bar blade guide bearing flats138 and 140, which respectively serve as hard stops against which arespective portion of the blade 31 abuts or contacts when reaching themaximum angular travel position in either direction.

With reference to FIGS. 7-11, the lifter bar blade guide bearing flats138 and 140 also serve as a fore-aft lifter bar blade movement guidethat can help guide the blade 31 and preferably the entire lifter bar 46during fore-aft movement of the blade 31 and bar 46 along the guide slot130 during fore-aft translation of the ball 64 along the channel 124 orbearing race 126 within the base 58 in a longitudinal or lengthwisedirection relative to the base 58, including during lifter bar assemblyto the base 58, during lifter bar self-adjustment relative to themolding apparatus 42 during core lifter installation, during core lifteruse, and/or during mold cycling during molding apparatus operation. Asdepicted by FIGS. 8 and 9, the lifter bar blade guide bearing flats 138and 140 also serve as lifter bar blade pivot abutments 145 and 147against which a respective side or wall of the blade 31 of the lifterbar 46 abuts or stops when the ball 64 is pivoted in a side-to-sidedirection within the channel 124 or bearing race 126 toward one of theflats 138 or 140 about its longitudinal rotational axis 156.

As is best shown in FIG. 9, each one of the flats 138 and 140 areoutwardly canted away from one another forming or defining an acuteincluded angle therebetween with each one of the flats 138 and 140thereby being outwardly beveled so as to prevent binding of the blade 31of lifter bar 46 sliding along a respective one of the flats 138 or 140by reducing static and dynamic friction therebetween. When the blade 31of the lifter bar 46 is pivoted in a fore-aft direction about fore-aftpivot axis 156 (FIGS. 9 and 11), at least one of the stops 91 and/or 93of corresponding shoulders 81 and 83 defined by guide channels 82 and 84of the lifter bar blade coupling head 68 abuts or stops against at leasta respective one of the stops 145 and/or 147 provided or defined by thelifter bar blade guide bearing flats 138 and/or 140 preventing the blade31 and ball 64 from the lifter bar 46 from further pivoting or rotation.Such outwardly canted or outwardly beveled flats 138 and 140 also helpprovide or define a more positive fore-aft pivoting directional stop 145and 147 when the stops 91 and 93 defined by lifter bar blade guidechannel shoulders 81 and 83 abut or bear against respective flats 138and 140 by providing a greater surface area of contact between therespective pairs of mating stops 91, 145 and 93, 147.

When the blade 31 of the lifter bar 46 is pivoted about the transversefore-aft pivot axis 156, the blade 31 preferably rotates or pivots aboutthe fore-aft lifter bar blade pivot axis 156 that extends generallyhorizontally and transversely through the ball 64 and the base 58 in afore-aft direction such as depicted in FIG. 11. With continued referenceto FIG. 11, the blade 31 of the lifter bar 46 of a core lifter 40 of thepresent invention can rotate or pivot about the fore-aft pivot axis 156such that the angle, β, between the central longitudinal base axis 135and the central longitudinal lifter bar blade axis 122 is no greaterthan 45°, preferably ±22.5° in the fore-aft direction forwardly orrearwardly of the central longitudinal base axis 135°. Whether pivotedin the fore-aft direction forwardly or rearwardly about the fore-aftpivot axis 156, at least one of the recessed guide-channel formingshoulders 81 and 83 defined by guide channels 82 and 84 formed in thesides 86 and 88 of the blade 31 of the lifter bar 46 function as ordefine fore-aft pivot or rotation stops 91 and 93 that limit the angularextent, β, of pivoting or rotation of the blade 31 and ball 64 about thefore-aft pivot axis 156 in the manner depicted in FIG. 11.

In the preferred embodiment shown in FIG. 11, the lifter bar 46,including its ball 64 and blade 31, can pivot or rotate forwardly in thefore-aft direction relative to the central longitudinal base axis 135°such that the central longitudinal lifter bar blade axis 122° forms anacute included angle, β, therebetween of at least 5°, preferably atleast 10°, and which can be as large as 20° as illustrated in FIG. 11.Although not shown in FIG. 11, the lifter bar 46, including its ball 64and blade 31, can pivot or rotate rearwardly in the fore-aft directionrelative to the central longitudinal base axis 135° such that thecentral longitudinal lifter bar blade axis 122° forms an acute includedangle, β, therebetween of at least 5°, preferably at least 10°, andpreferably which is at least about 20°. In one preferred core lifterembodiment, β, has a range of at least ±10° in the fore-aft directiondepicted by arrow 105 in FIG. 11. In another preferred embodiment, β,has a range of at least ±15° in the fore-aft direction depicted by arrow105 in FIG. 11. In still another preferred embodiment, β, has a range ofat least about ±20°, e.g., ±20°±5°.

The substantially spherical outer profile of the ball 64 enables thelifter bar 46 of the core lifter 40 of the present invention to pivotabout the fore-aft axis 156 extending longitudinally relative to thebase 58 through the center point 154 pivot or pin 108 at least 10degrees, preferably at least 15 degrees and more preferably at least 20degrees in the release direction, e.g., in or along the direction of thebearing race 126. Where lacking a pin 108, the fore-aft axis extendsthrough a center of the ball 64 generally perpendicular to thelengthwise extent of the lifter bar 46 and along a lengthwise fore-aftdirection along the guide shoe 66 or bearing race 126.

In a preferred core lifter embodiment, the substantially spherical outerprofile of the ball 64 enables the lifter bar 46 of the core lifter 40to pivot about the fore-aft pivot axis 156 extending through the pivotor pin 108 at least ±10 degrees, preferably at least ±15 degrees andmore preferably at least ±20 degrees in the release direction, e.g., inor along the direction of the guide shoe 66 or bearing race 126. Thesubstantially spherical outer profile of the ball 64 also enables thelifter bar or core blade 31 of the core lifter 40 to tilt fromside-to-side about a transverse axis extending longitudinally throughthe bearing race 126 and through the center of the ball 64 at least 5degrees, preferably at least 10 degrees and more preferably at least 15degrees generally transverse to the release direction, e.g., generallytransverse to the lengthwise direction of the bearing race 126. In apreferred embodiment, the substantially spherical outer profile of theball 64 enables the lifter bar or core blade 64 of the core lifter 40 totilt from side-to-side about an axis extending longitudinally throughthe bearing race 126 and through the center of the ball 64 at least ±5degrees, preferably at least ±10 degrees and more preferably at least±15 degrees generally transverse to the release direction, e.g.,generally transverse to the lengthwise direction of the bearing race126. A lifter bar or core blade 46 of such a core lifter 40 of thepresent invention is better able to swivel, pivot, rotate and moveside-to-side in adjusting at it slides in and along a guide slot formedin the mold that is an angled primary release direction slot of compoundangle construction without binding.

The present invention advantageously is therefore directed to a corelifter 40 or 40′ that is of fully articulating construction by beingable to both tilt and swivel relative to the base 58 and whichpreferably also is of substantially self-aligning construction byfurther being able to slidably move in a fore-aft direction along thelongitudinal or lengthwise direction of the base 58 while also beingable to move side-to-side independently of tilting or swiveling. Such acore lifter 40 or 40′ of the present invention is a fully articulatingcore lifter 40 or 40′ by its core blade or lifter bar 46 or 46′, and thecore 48 or 48′ carried thereby, being able to both tilt and swivel andpreferably which also is of substantially self-aligning construction bythe core blade or lifter bar 46 further being able to slidably move in afore-aft direction while also being able to move side-to-sideindependently of tilting or swiveling during installation of such a corelifter 40 or 40′ into a molding apparatus 42 and during use of the corelifter 40 or 40′ during molding apparatus operation. The presentinvention therefore also is directed to a core lifter 40 or 40′ that isof fully articulating construction by the core 48 or 48′ of the lifter40 or 40′ and the core blade or lifter bar 46 or 46′ carrying the core48 or 48′ being able to both tilt and swivel and preferably which alsois of substantially self-aligning construction by the core 48 or 48′ andcore blade or lifter bar 46 or 46′ further being able to slidably movein a fore-aft direction while also being able to move side-to-sideindependently of tilting or swiveling during core lifter installationand molding apparatus operation.

The present invention advantageously is therefore directed to anarticulating, preferably fully articulating self-aligning core lifter 40for a formable material forming apparatus that preferably is a formablematerial molding apparatus, e.g. plastic molding apparatus, which morepreferably is a plastics injection molding apparatus, e.g., plasticinjection mold. Such a lifter of the present invention is able toself-align relative to a slot of the molding apparatus and/or pocket inthe undercut of the molding apparatus by being angularly adjustable orself-adjusting up to 20 degrees in the release direction as depicted inFIG. 11 and also being angularly adjustable or self-adjusting in anyother 360-degree direction at least 5 degrees, e.g., ±5 degrees, andpreferably at least 10 degrees, e.g., ±10 degrees without binding andwithout requiring a guided ejector system (preferably without using aguided ejector system).

Such a lifter of the present invention being able to self-align relativeto a slot formed in a mold of the apparatus in which the core blade 46is slidably received and/or pocket in the undercut of a mold of theapparatus by being angularly adjustable or self-adjusting up to 20degrees in the release direction as depicted in FIG. 11 and beingangularly adjustable or self-adjusting in any other direction between10-25 degrees without binding and without requiring a guided ejectorsystem (preferably without using a guided ejector system). In apreferred embodiment, such a lifter of the present invention self-alignsto or in the mold slot or pocket of the undercut by being angularlyadjustable or self-adjusting up to ±20 degrees in the release directionand being angularly adjustable or self-adjusting in any other directionbetween ±10-25 degrees without binding and without requiring a guidedejector system (preferably without using a guided ejector system).

A core lifter 40 of the present invention also is scalable in corelifter, e.g., lifter bar or core blade, sizes or lengths of between 1and 50 millimeters. Such a core lifter 40 can have a length or size lessthan 5 millimeters, preferably less than 2.5 millimeters, and morepreferably less than 2 millimeters. Such a core lifter 40 is upwardlyscalable to sizes or lengths greater than 40 millimeters, preferablygreater than 50 millimeters, and more preferably greater than 60millimeters depending on mold size and other factors.

Understandably, the present invention has been described above in termsof one or more preferred embodiments and methods. It is recognized thatvarious alternatives and modifications may be made to these embodimentsand methods that are within the scope of the present invention. Variousalternatives are contemplated as being within the scope of the presentinvention. It is also to be understood that, although the foregoingdescription and drawings describe and illustrate in detail one or morepreferred embodiments of the present invention, to those skilled in theart to which the present invention relates, the present disclosure willsuggest many modifications and constructions, as well as widelydiffering embodiments and applications without thereby departing fromthe spirit and scope of the invention as defined hereby and herein.

It is claimed:
 1. A core lifter for a molding apparatus, the core liftercomprising: (a) a core lifter bar comprised of an elongate core lifterblade, a core lifter bar coupler carried by the core lifter blade, and ajoint configured for side-to-side movement of one of the core lifterblade and the core lifter bar coupler relative to the other one of thecore lifter blade and the core lifter bar coupler; and (b) an elongatecore lifter base carried by a portion of the molding apparatus, the corelifter bar base comprised of a core lifter bar coupling receiver formedtherein that is configured for receiving the core lifter bar coupler,the core lifter bar coupler received in the core lifter bar couplingreceiver, and the core lifter bar blade extending outwardly from thebase; and wherein the core lifter blade pivots longitudinally, moveslongitudinally, and moves side-to-side relative to the core lifter base.2. The core lifter of claim 1, further comprising a core comprised of athree-dimensionally contoured molding face, the core removably attachedto the core lifter blade via a second joint disposed at an end of thecore lifter blade.
 3. The core lifter of claim 1, wherein the corelifter base coupling receiver comprises an elongate core lifter barcoupler receiving channel formed in the core lifter base that extendslengthwise relative to the core lifter base, and a pair of elongate,opposed, generally parallel, and inclined lifter blade guide flats thatdefine an elongate lifter bar guide slot therebetween, the lifter barguide slot disposed in communication with the core lifter bar couplerreceiving channel, the lifter bar guide slot extending longitudinallyrelative to the core lifter base, and wherein the lifter blade guideflats slidably guide the lifter blade along the lifter bar guide slot asthe core lifter bar coupler moves longitudinally along the core lifterbar coupler receiving channel during longitudinal movement of the corelifter blade relative to the core lifter base.
 4. The core lifter ofclaim 3, wherein the lifter blade guide flats are oppositely inclinedrelative to one another defining an acute included angle therebetween.5. The core lifter of claim 1, wherein the core lifter base has anelongate channel of circular-cross section formed therein incommunication with an elongate lifter blade guide slot; and wherein thecore lifter bar coupler comprises a spherical core lifter bar couplingball received in the channel, core lifter bar coupling ball floatingtransversely relative to the lifter blade enabling side-to-sidetranslation of the core lifter blade relative to the core lifter base.6. The core lifter of claim 5, wherein the core lifter bar coupling ballcomprises a carbide ball bearing.
 7. The core lifter of claim 1 whereinthe core lifter base has an elongate and substantially straight corelifter bar coupler receiving channel in communication with an elongateand substantially straight core lifter bar blade guide slot overlyingthe core lifter bar coupler receiving channel, and wherein the corelifter blade pivots in a fore-aft direction relative to the core lifterbase in a direction generally parallel to the core lifter bar couplerreceiving channel, swivels relative to the core lifter base about alongitudinal central axis of the core lifter blade, rotates relative tothe core lifter base in a side-to-side direction generally transverselyto the core lifter bar coupler receiving channel, translateslongitudinally relative to the core lifter base by moving along the corelifter bar coupler receiving channel with part of the core lifter bladeextending upwardly through the core lifter blade guide slot, andtranslates transversely relative to the core lifter base by moving in asideways direction relative to the core lifter base.
 8. The core lifterof claim 1, wherein the core lifter bar coupler comprises a core lifterbar coupling ball attached to the core lifter blade by the joint,wherein the joint is configured so the core lifter bar coupling balltransversely floats relative to the core lifter blade thereby enablingmovement of one of the core lifter blade and core lifter bar couplingball generally transversely relative to the other one of the core lifterblade and core lifter bar coupling ball and generally transverselyrelative to the direction of longitudinal movement of the core lifterblade relative to the core lifter base.
 9. The core lifter of claim 1,wherein the core lifter base is removably fastened to the portion of themolding apparatus by a plurality of fasteners.
 10. The core lifter ofclaim 1, wherein the core lifter bar coupler comprises a core lifter barcoupling ball carried by the core lifter bar blade, wherein the base hasa core lifter bar coupling receiver formed therein that comprises anelongate substantially straight channel that receives the core lifterbar coupling ball therein, and wherein the core lifter blade is elongateand substantially straight.
 11. The core lifter of claim 10, wherein thecore lifter bar coupling ball is removably attached to one end of thecore lifter bar blade.
 12. The core lifter of claim 1, wherein the corelifter bar receiver formed in the base comprises an elongate lifter barguide slot formed in the core lifter base that overlies and communicateswith an elongate core lifter bar coupler receiving channel formed in thecore lifter base having a generally circular cross-section, wherein thecore lifter bar coupler is operatively connected to the core lifterblade by the joint, and wherein the core lifter bar coupler has agenerally spherical core lifter bar coupling ball received in the corelifter bar coupler receiving channel.
 13. The core lifter of claim 12,wherein the core lifter bar coupling ball comprises a ball bearingcomposed of carbide.
 14. The core lifter of claim 12, wherein the corelifter blade is substantially straight, and the elongate core lifter barcoupler receiving channel is an elongate substantially straight bearingrace formed in the core lifter base in which the ball bearing slidablymoves during movement of the core lifter blade longitudinally relativeto the core lifter base, and wherein the joint is configured forside-to-side movement of the core lifter blade relative to the corelifter bar coupler in a direction generally transverse to thelongitudinal movement of the core lifter blade relative to the corelifter base thereby enabling side-to-side movement of the core lifterblade relative to the core lifter base in the direction transverse tothe longitudinal movement of the core lifter blade relative to the corelifter base t.
 15. The core lifter of claim 1, wherein the core lifterbar is movably attached to the core lifter base enabling sidewaysrotation of the core lifter blade relative to a transverse direction ofthe core lifter base along about a pivot axis extending generallyparallel to a longitudinal centerline of the core lifter base at least±10 degrees about the pivot axis.
 16. The core lifter of claim 1,wherein the core lifter bar is movably attached to the core lifter baseenabling fore-aft pivoting of the core lifter blade relative to alengthwise direction of the core lifter base along about a pivot axisextending transversely to a longitudinal centerline of the core lifterbase at least ±10 degrees about the pivot axis.
 17. The core lifter ofclaim 1, wherein the core lifter bar is movably attached to the corelifter base enabling swiveling of the core lifter blade relative to thecore lifter base along about a central longitudinal axis of the corelifter blade.
 18. The core lifter of claim 1, wherein the core lifterbar is movably attached to the core lifter base enabling tilting of thecore lifter blade relative to the core lifter base along about a tiltaxis of the core lifter base.
 19. A core lifter for a molding apparatus,the core lifter comprising: (a) a core lifter bar comprised of anelongate substantially straight core lifter blade, a generally sphericalcore lifter bar coupling ball, and a joint configured for side-to-sidetranslation of one of the core lifter blade and core lifter bar couplingball relative to the other one of the core lifter blade and core lifterbar coupling ball; (b) an elongate core lifter base carried by a portionof the molding apparatus, an elongate substantially straight channel ofcircular cross-section formed in the core lifter base for receiving thecore lifter bar coupling ball, and an elongate substantially straightcore lifter blade guide slot overlying and in communication with thecore lifter bar coupling ball receiving channel; and wherein the corelifter blade (i) pivots relative to the core lifter base about the corelifter bar coupling ball received in the core lifter bar coupling ballreceiving channel in a direction generally parallel to the core lifterbar coupling ball receiving channel, (ii) rotates generally transverselyrelative to the core lifter base, (iii) swivels relative to the corelifter base about a longitudinal axis of the core lifter blade, (iv)translates side-to-side relative to the core lifter base, and (v)translates longitudinally relative to the core lifter base by the corelifter bar coupling ball riding along the core lifter bar coupling ballreceiving channel.
 20. The core lifter of claim 19, wherein the corelifter blade guide slot is defined by a pair of elongate, substantiallystraight, and generally parallel core lifter blade guide flats inclinedrelative to one another defining an acute included angle therebetween,and wherein the angle of generally transverse rotation of core lifterblade relative to the core lifter base is limited by the core lifterblade stopping or abutting against one of the core lifter blade guideflats.
 21. The core lifter of claim 19, wherein the joint of the corelifter bar configures the core lifter coupling ball to float relative tothe core lifter blade for relative sideways translational movementtherebetween.
 22. The core lifter of claim 19, wherein the core lifterblade pivots ±20° relative to an axis extending through a center of thecore lifter bar coupling ball generally parallel to a lengthwise extentof the core lifter bar coupling ball receiving channel.
 23. The corelifter of claim 19, wherein the core lifter blade rotates ±10° relativeto an axis extending through a center of the core lifter bar couplingball generally transverse to a lengthwise extent of the core lifter barcoupling ball receiving channel.
 24. The core lifter of claim 19,wherein the core lifter bar coupling ball comprises a carbide ballbearing and the core lifter bar coupling ball receiving channelcomprises a bearing raceway.
 25. A core lifter for a molding apparatus,the core lifter comprising: (a) a core lifter bar comprised of anelongate substantially straight core lifter blade, and a core lifter barcoupling ball carried by the core lifter blade; (b) an elongate corelifter base carried by a portion of the molding apparatus, an elongatesubstantially straight channel of circular cross-section formed in thecore lifter base for receiving the core lifter bar coupling ball, and anelongate substantially straight core lifter blade guide slot overlyingand in communication with the core lifter bar receiving ball receivingchannel; and wherein the core lifter blade, core lifter bar couplingball, and core lifter base are configured so the core lifter blade (i)pivots along the core lifter blade guide slot about the core lifter barcoupling ball received in the core lifter bar coupling ball receivingchannel in a direction generally parallel to the core lifter barcoupling ball receiving channel and the core lifter blade guide slot,(ii) rotates generally transversely relative to the core lifter barcoupling ball receiving channel and the core lifter blade guide slot,(iii) swivels about a longitudinal axis of the core lifter blade, (iv)translates side-to-side relative to the core lifter base, and (v)translates longitudinally relative to the core lifter base.